ESAB ET 201i DC Inverter Arc Welder User manual

Brand: ESAB

Model: ET 201i DC Inverter Arc Welder

Category: Welding System

Type: User manual

Art # A-13034

3163339

English

Canadien Français

esab.com

ET 201i DC

Inverter Arc Welder

Operating

Manual

Revision: AA Issue Date: March 30, 2016 Manual No.: 0-5452

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new ESAB product. We are proud to have you as our customer and will

strive to provide you with the best service and reliability in the industry. This product is backed by

our extensive warranty and world-wide service network. To locate your nearest distributor or service

agency, visit us on the web at www.esab.com

This Operating Manual has been designed to instruct you on the correct use and operation of your

ESAB product. Your satisfaction with this product and its safe operation is our ultimate concern.

Therefore please take the time to read the entire manual, especially the Safety Precautions. They

will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

ESAB is a Global Brand of Welding Products.

We distinguish ourselves from our competition through market-leading, dependable products that

have stood the test of time. We pride ourselves on technical innovation, competitive prices, excel-

lent delivery, superior customer service and technical support, together with excellence in sales

and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer

working environment within the welding industry.

WARNING

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or

servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufac-

turer assumes no liability for its use.

Welding Power Supply

Operating Manual Number 0-5452 for:

ESAB ET 201i DC Power Source Arc Welder Part No. W1003806

ESAB ET 201i DC System with Stick/TIG Kit & Case Part No. W1003807

Published by:

ESAB Group Inc.

2800 Airport Rd.

Denton, TX 76208

www.esab.com

ESAB

Reproduction of this work, in whole or in part, without written permission of the publisher

is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss

or damage caused by any error or omission in this Manual, whether such error results from

negligence, accident, or any other cause.

For Printing Material Specication refer to document 47x1909.

Publication Date: March 30, 2016

Revision Date:

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

Equipment Serial #: ____________________________________

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with

the principles of operation and safe practices for arc welding and cutting equipment,

we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cut-

ting, and Gouging,” Form 0-5407. Do NOT permit untrained persons to install, operate,

or maintain this equipment. Do NOT attempt to install or operate this equipment until

you have read and fully understand these instructions. If you do not fully understand

these instructions, contact your supplier for further information. Be sure to read the

Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompany-

ing labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions

provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should

not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately.

Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written

request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The

user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty

maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility

designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR

OPERATING.

PROTECT YOURSELF AND OTHERS!

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.

VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.

ATTENTION

Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement.

Si vous n’avez pas une connaissance approfondie des principes de fonctionnement

et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous

vous suggérons de lire notre brochure « Precautions and Safe Practices for Arc Weld-

ing, Cutting and Gouging, » Formulaire 0-5407. Ne permettez PAS aux personnes non

qualiées d’installer, d’opérer ou de faire l’entretien de cet équipement. Ne tentez PAS

d’installer ou d’opérer cet équipement avant de lire et de bien comprendre ces in-

structions. Si vous ne comprenez pas bien les instructions, communiquez avec votre

fournisseur pour plus de renseignements. Assurez-vous de lire les Règles de Sécurité

avant d’installer ou d’opérer cet équipement.

RESPONSABILITÉS DE L’UTILISATEUR

Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagnement et/ou

les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions fournies. Vous devez

faire une vériﬁcation périodique de l’équipement. Ne jamais utiliser un équipement qui ne fonctionne pas bien ou n’est pas

bien entretenu. Les pièces qui sont brisées, usées, déformées ou contaminées doivent être remplacées immédiatement.

Dans le cas où une réparation ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande

de conseil de service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement.

Cet équipement ou ses pièces ne doivent pas être modiﬁés sans permission préalable écrite par le fabricant. L’utilisateur

de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte, un entretien fautif, des

dommages, une réparation incorrecte ou une modiﬁcation par une personne autre que le fabricant ou un centre de service

désigné par le fabricant.

ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT

D’INSTALLER OU D’OPÉRER L’UNITÉ.

PROTÉGEZ-VOUS ET LES AUTRES!

TABLE OF CONTENTS

SECTION 1: SAFETY ........................................................................................ 1-1

1.0 Safety Precautions .......................................................................................... 1-1

SECTION 2:

INTRODUCTION ...................................................................................... 2-1

2.01 How to Use This Manual ................................................................................. 2-1

2.02 Equipment Identiﬁcation ................................................................................. 2-1

2.03 Receipt of Equipment ...................................................................................... 2-1

2.04 Description ..................................................................................................... 2-1

2.05 Transportation Methods .................................................................................. 2-1

2.06 Duty Cycle ....................................................................................................... 2-2

2.07 Speciﬁcations ................................................................................................. 2-2

SECTION 3:

INSTALLATION ....................................................................................... 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location .......................................................................................................... 3-1

3.03 Electrical Input Connections ........................................................................... 3-2

3.04 Electromagnetic Compatibility ........................................................................ 3-4

3.05 Setup for Welding ........................................................................................... 3-6

3.06 STICK (SMAW) Setup ..................................................................................... 3-6

3.07 Victor Regulator .............................................................................................. 3-8

3.08 Leak Testing the System ................................................................................. 3-9

3.09 LIFT TIG (GTAW) Setup................................................................................. 3-10

3.10 HF TIG (GTAW) Setup ................................................................................... 3-12

3.11 When You Finish Using the Regulator ........................................................... 3-14

3.12 Storage of the Regulator ............................................................................... 3-14

SECTION 4:

OPERATION ........................................................................................... 4-1

4.01 Instruction ...................................................................................................... 4-1

4.02 Front Panel ..................................................................................................... 4-1

4.03 Welding Current Control Explanation .............................................................. 4-3

4.04 STICK (SMAW) Electrode Polarity................................................................... 4-4

4.05 Effects of Stick Welding Various Materials ...................................................... 4-4

4.06 GTAW Electrode Polarity ................................................................................. 4-5

4.07 Guide for Selecting Filler Wire ........................................................................ 4-5

4.08 Tungsten Electrode Current Ranges ................................................................ 4-5

4.09 Shielding Gas Selection .................................................................................. 4-5

4.10 Tungsten Electrode Types ............................................................................... 4-6

4.11 TIG Welding Parameters for Steel ................................................................... 4-6

4.12 Arc Welding Practice ....................................................................................... 4-6

4.13 Welding Position ............................................................................................. 4-6

4.14 Joint Preparations ........................................................................................... 4-8

4.15 Arc Welding Technique ................................................................................... 4-9

4.16 The Welder ...................................................................................................... 4-9

4.17 Striking the Arc ............................................................................................... 4-9

TABLE OF CONTENTS

4.18 Arc Length ...................................................................................................... 4-9

4.19 Rate of Travel .................................................................................................. 4-9

4.20 Making Welded Joints ................................................................................... 4-10

4.21 Distortion ...................................................................................................... 4-12

4.22 The Cause of Distortion ................................................................................ 4-12

4.23 Overcoming Distortion Effects ...................................................................... 4-12

SECTION 5:

SERVICE ............................................................................................... 5-1

5.01 Maintenance and Inspection ........................................................................... 5-1

5.02 STICK (SMAW) Welding Problems ................................................................ 5-2

5.03 TIG Welding Problems ................................................................................... 5-3

5.04 Power Source Problems ................................................................................ 5-4

SECTION 6:

KEY SPARE PARTS .................................................................................. 6-1

6.01 Replacement Parts ................................................................................................ 6-1

APPENDIX 1: OPTIONS AND ACCESSORIES ............................................................ A-1

APPENDIX 2: SYSTEM SCHEMATIC ...................................................................... A-2

TABLE OF CONTENTS

This Page Intentionally Blank

ET 201i DC

0-5452 SAFETY

1-1

1.0 Safety Precautions

Users of ESAB welding and plasma cutting 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 or plasma cutting 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 welding or plasma

cutting 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 welding or plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

- no unauthorized person 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, ame proof

clothing, safety gloves.

- Do not wear loose tting 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 qualied electrician.

- Appropriate re extinguishing equipment must be clearly marked and close at hand.

- Lubrication and maintenance must not be carried out on the equipment during operation.

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation in ac-

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

SECTION 1: SAFETY

ET 201i DC

SAFETY 0-5452

1-2

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 (ground) the welding or plasma cutting 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 / plasma cutting screen and lter lens and wear

protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmus 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

This product is solely intended for welding. Any other use may result in

personal injury and / or equipment damage.

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 poten-

tial diculties in ensuring electromagnetic compatibility

of class A equipment in those locations, due to conducted

as well as radiated disturbances.

CAUTION

Read and understand the instruction manual before

installing or operating.

CAUTION

Do not use the power source for thawing frozen pipes.

WARNING

ET 201i DC

0-5452 INTRODUCTION

2-1

SECTION 2:

INTRODUCTION

2.01 How to Use This Manual

This Manual usually applies to the part numbers listed on

page i. To ensure safe operation, read the entire manual,

including the chapter on safety instructions and warnings.

Throughout this manual, the word WARNING, CAUTION

and NOTE may appear. Pay particular attention to the in-

formation provided under these headings. These special

annotations are easily recognized as follows:

NOTE!

An operation, procedure, or background informa-

tion which requires additional emphasis or is

helpful in ecient operation of the system.

WARNING

A procedure which, if not properly followed, may

cause injury to the operator or others in the operat-

ing area.

CAUTION

A procedure which, if not properly followed, may

cause damage to the equipment.

WARNING

Gives information regarding possible electrical shock

injury. Warnings will be enclosed in a box such as this.

DANGER

Means immediate hazards which, if not avoided,

will result in immediate, serious personal injury or

loss of life.

You will also notice icons from the safety section appear-

ing throughout the manual. These are to advise you of

speciﬁc types of hazards or cautions related to the portion

of information that follows. Some may have multiple

hazards that apply and would look something like this:

2.02 Equipment Identiﬁcation

The unit’s identiﬁcation number (speciﬁcation or part

number), model, and serial number usually appear on

a nameplate attached to the machine. Equipment which

does not have a nameplate attached to the machine is

identiﬁed only by the speciﬁcation or part number printed

on the shipping container. Record these numbers for

future reference.

2.03 Receipt of Equipment

When you receive the equipment, check it against the

invoice to make sure it is complete and inspect the

equipment for possible damage due to shipping. If there is

any damage, notify the carrier immediately to ﬁle a claim.

Furnish complete information concerning damage claims

or shipping errors to the location in your area listed in the

inside back cover of this manual. Include all equipment

identiﬁcation numbers as described above along with a

full description of the parts in error.

2.04 Description

The ET 201i DC is a compact inverter welding machine that

has inﬁnitely adjustable welding current from 10 to 200

amps. It has LIFT TIG (GTAW) and HF TIG (GTAW) welding

modes that offer stable TIG welding characteristics with

an optimized start TIG sequence to initiate the welding arc

when used with a suitable TIG torch and shielding gas.

This model has advanced TIG features including an 8 Pin

Amp Plug for remote control devices, down slope, 2T /

4T controls, and gas solenoid operation. It also has a

STICK (SMAW) welding mode which uses standard gen-

eral purpose STICK (SMAW) 3/32” (2.5mm) electrodes

for light gauge work, generally less than 1/8” (3.2mm)

thick and STICK (SMAW) 1/8” (3.2mm) electrodes for

heavier material.

2.05 Transportation Methods

WARNING

Disconnect input power conductors from de-

energized supply line before moving the welding

Power Source.

Lift Power Source with handle on top of case. Use

handcart or similar device of adequate capacity. If

using a fork lift vehicle, secure the Power Source on

a proper skid before transporting.

ET 201i DC

INTRODUCTION 0-5452

2-2

2.06 Duty Cycle

The rated duty cycle of a Welding Power Source, is the percentage of a ten minute time period that it may be operated

at its rated output current without exceeding the temperature limits of the insulation of the component parts. To explain

the 10 minute duty cycle period, suppose a Welding Power Source is designed to operate with a 30% duty cycle at

160 amperes and 26.4 volts. This means that it has been designed and built to provide the rated amperage (160A) for

3 minutes, i.e. arc welding time, out of every 10 minute period (30% of 10 minutes is 3 minutes). During the other 7

minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool.

2.07 Speciﬁcations

Power Source Part Number W1003806

Mains Power

Nominal Supply Voltage AC 115V AC 208/230V

Number of Phases Single Phase Single Phase

Input Voltage Range AC 104- 127V AC 187- 253V

Nominal Supply Frequency 50/60 Hz 50/60 Hz

Effective Input Current (l1eff) for STICK (SMAW) Welding 18.3 Amps 15.8/14.2 Amps

Effective Input Current (l1eff) for LIFT TIG/HF TIG (GTAW)

Welding

16.4 Amps 12.3/11.1 Amps

Maximum Input Current (l1 max) for STICK (SMAW) Welding ∆ 27.2 Amps ∆ 35.2/31.6 Amps

Maximum Input Current (l1 max) for LIFT TIG/HF TIG (GTAW)

Welding

∆ 23.2 Amps ∆ 24.6/22.1 Amps

Single Phase Generator Requirements [Continuous rating

at nominal supply voltage with maximum output for STICK

(SMAW) welding]

4 KVA 7.3 KVA

Welding Output

Welding Current Range Stick: 10 - 125 Amps

TIG: 10 - 160 Amps

Stick/TIG:

10 - 200 Amps

Nominal DC Open Circuit Voltage (OCV) 71V 71V

Welding Output, 104º F (40º C), 10 min.

(Quoted ﬁgures refer to STICK (SMAW) output)

100A @ 45%, 24.0V

87A @ 60%, 23.5V

68A @ 100%, 22.7V

200A @ 20%, 28V

116A @ 60%, 24.6V

90A @ 100%, 23.6V

Rated Input Current (A)

For STICK (SMAW) Welding

27.2A

Io = 100A @ 24.0V

35.2/31.6A

Io = 200A @ 28V

Rated Input Current (A)

For LIFT TIG (GTAW) Welding

23.2A

Io = 125A @ 15.0V

24.6/22.1A

Io = 200A @ 18V

Rated Output for STICK (SMAW) Welding 24.0V, 100A @ 45% 28V, 200A @ 20%

Rated Output for LIFT TIG/HF TIG (GTAW) Welding 15.0V, 125A @ 50% 18V, 200A @ 25%

Duty Cycle (%) 45% @ 100A 20% @ 200A

Welder Type Inverter Power Source

Output Terminal Type Heavy Duty Dinse

Classiﬁcation

Protection Class IP21S

Standards CSA E60974-1

EN50199

Cooling Method Fan Cooled

Dimensions and Weight

Welding Power Source Mass 22 lb. (10 kg)

Welding Power Source Dimensions (Height x Width x Depth) H 9.0” x W 5.3” x D 17.7”

(H230mm x W135mm x D450mm)

ET 201i DC

0-5452 INTRODUCTION

2-3

NOTE!

The recommended time delay fuse or circuit breaker size is 30 amp. An individual branch circuit capable of carrying 30 amperes

and protected by fuses or circuit breaker is recommended for this application. Fuse size is based on not more than 200 percent of

the rated input amperage of the welding power source (Based on Article 630, National Electrical Code).

ESAB continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the

specications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equip-

ment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

The values specied in the table above are optimal values, your values may dier. Individual equipment may dier from the

above specications due to in part, but not exclusively, to any one or more of the following; variations or changes in manufac-

tured components, installation location and conditions and local power grid supply conditions.

The Welding power source is of a drooping characteristic. The thermal protection switch is rated at 75° C.

ET 201i DC

INTRODUCTION 0-5452

2-4

This Page Intentionally Blank

ET 201i DC

0-5452 INSTALLATION

3-1

3.01 Environment

This unit is designed for use in environments with increased hazard of electric shock. Examples of environments with

increased hazard of electric shock are:

A. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a

cramped (kneeling, sitting or lying) position with physical contact with conductive parts.

B. In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable

or accidental contact by the operator.

C. In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human

body and the insulation properties of accessories.

Environments with increased hazard of electric shock do not include places where electrically conductive parts in the

near vicinity of the operator, which can cause increased hazard, have been insulated.

This equipment can't be operated in rain or snow.

3.02 Location

Be sure to locate the welder according to the following guidelines:

• In areas, free from moisture and dust.

• Ambient temperature between 14°F (-10°C) to 104° F (40° C).

• In areas, free from oil, steam and corrosive gases.

• In areas, not subjected to abnormal vibration or shock.

• In areas, not exposed to direct sunlight or rain.

• Place at a distance of 12” (300mm) or more from walls or similar that could restrict natural air ﬂow for cooling.

WARNING

ESAB advises that this equipment be electrically connected by a qualied electrician.

SECTION 3:

INSTALLATION

ET 201i DC

INSTALLATION 0-5452

3-2

3.03 Electrical Input Connections

WARNING

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.

DO NOT TOUCH live electrical parts.

SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lock-out/tagging

procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting

off and red-tagging circuit breaker or other disconnecting device.

• Electrical Input Requirements

Operate the welding power source from a single-phase 50/60 Hz, AC power supply. The input voltage must match one

of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility

for information about the type of electrical service available, how proper connections should be made, and inspection

required. The line disconnect switch provides a safe and convenient means to completely remove all electrical power

from the welding power supply whenever necessary to inspect or service the unit.

Do not connect an input (WHITE or BLACK) conductor to the ground terminal.

Do not connect the ground (GREEN) conductor to an input line terminal.

Refer to Figure 3-1:

1. Connect end of ground (GREEN or GREEN/YELLOW) conductor to a suitable ground. Use a grounding method that

complies with all applicable electrical codes.

2. Connect ends of line 1 (BLACK) and line 2 (WHITE) input conductors to a de-energized line disconnect switch.

3. Use Table 3-1 as a guide to select line fuses for the disconnect switch.

Input Voltage Circuit Breaker or Fuse Size

115V 30A

208-230V 50A

Table 3-1: Fuse Guide

CAUTION

The time-delay fuses or circuit breaker of an individual branch circuit may have nuisance tripping when welding with this

product due to the amperage rating of the time-delay fuses or circuit breaker.

ET 201i DC

0-5452 INSTALLATION

3-3

Input Power

Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides

pre-charging for the input capacitors. A relay in the Power Control Assembly (PCA) will turn on after the input capacitors

have charged to operating voltage (after approximately 5 seconds)

NOTE!

Damage to the PCA could occur if 253 VAC or higher is applied to the Primary Power Cable.

Model

Primary Supply Lead

Size (Factory Fitted)

Minimum Primary

Current Circuit Size

(Vin/Amps)

Current & Duty Cycle

LIFT TIG/ HF TIG

(GTAW)

STICK (SMAW)

ET 201i DC 12 AWG (3.3mm²)

115V/30A - 100A @ 45%

115V/30A 150A @ 35%

208-230V/25A - 200A @ 20%

208-230V/25A 200A @ 25%

Table 3-2: Primary Circuit Sizes to Achieve Maximum Current

Welding Power Supply

Primary Power Cable

120

20A,1Ø

15A,1Ø

208-230V, 50A,1Ø

The Adapters enable

connection to all these

power outlets

Art# A-09789

Figure 3-1: Electrical Input Connections

ET 201i DC

INSTALLATION 0-5452

3-4

3.04 Electromagnetic Compatibility

WARNING

Extra precautions for Electromagnetic Compatibility

may be required when this Welding Power Source is

used in a domestic situation.

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the welding

equipment according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall

be the responsibility of the user of the welding equipment

to resolve the situation with the technical assistance of

the manufacturer. In some cases this remedial action

may be as simple as earthing the welding circuit, see

NOTE below. In other cases it could involve constructing

an electromagnetic screen enclosing the Welding Power

Source and the work, complete with associated input

ﬁlters. In all cases, electromagnetic disturbances shall be

reduced to the point where they are no longer Trouble-

some.

B. Assessment of Area

Before installing welding equipment, the user shall make

an assessment of potential electromagnetic problems in

the surrounding area. The following shall be taken into

account.

1. Other supply cables, control cables, signaling and

telephone cables; above, below and adjacent to the

welding equipment.

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial

equipment.

5. The health of people around, e.g. the use of pace-

makers and hearing aids.

6. Equipment used for calibration and measurement.

7. The time of day that welding or other activities are to

be carried out.

8. The immunity of other equipment in the environment:

the user shall ensure that other equipment being used

in the environment is compatible: this may require

additional protection measures.

The size of the surrounding area to be considered will

depend on the structure of the building and other activities

that are taking place. The surrounding area may extend

beyond the boundaries of the premises.

C. Methods of Reducing Electromagnetic Emissions

1. Mains Supply

Welding equipment should be connected to the

mains supply according to the manufacturer’s

recommendations. If interference occurs, it may be

necessary to take additional precautions such as

ﬁltering of the mains supply. Consideration should

be given to shielding the supply cable of permanently

installed welding equipment in metallic conduit or

equivalent. Shielding should be electrically continuous

throughout its length. The shielding should be

connected to the Welding Power Source so that good

electrical contact is maintained between the conduit

and the Welding Power Source enclosure.

2. Maintenance of Welding Equipment

The welding equipment should be routinely maintained

according to the manufacturer’s recommendations. All

access and service doors and covers should be closed

and properly fastened when the welding equipment

is in operation. The welding equipment should not

be modiﬁed in any way except for those changes

and adjustments covered in the manufacturer’s

instructions. In particular, the spark gaps of arc

striking and stabilizing devices should be adjusted

and maintained according to the manufacturer’s

recommendation

3. Welding Cables

The welding cables should be kept as short as possible

and should be positioned close together, running at

or close to the ﬂoor level.

4. Equipotential Bonding

Bonding of all metallic components in the welding

installation and adjacent to it should be considered.

However, metallic components bonded to the work

piece will increase the risk that the operator could

receive a shock by touching the metallic components

and the electrode at the same time. The operator

should be insulated from all such bonded metallic

components.

ET 201i DC

0-5452 INSTALLATION

3-5

5. Earthing of the Work Piece

Where the work piece is not bonded to earth for

electrical safety, nor connected to earth because of its

size and position, e.g. ship’s hull or building steelwork,

a connection bonding the work piece to earth may

reduce emissions in some, but not all instances. Care

should be taken to prevent the earthing of the work

piece increasing the risk of injury to users, or damage

to other electrical equipment. Where necessary, the

connection of the work piece to earth should be made

by direct connection to the work piece, but in some

countries where direct connection is not permitted, the

bonding should be achieved by suitable capacitance,

selected according to national regulations.

6. Screening and Shielding

Selective screening and shielding of other cables

and equipment in the surrounding area may alleviate

problems of interference. Screening the entire

welding installation may be considered for special

applications.

ET 201i DC

INSTALLATION 0-5452

3-6

3.05 Setup for Welding

NOTE!

Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to work piece and

electrode lead is used to hold electrode. Wide safety margins provided by the design ensure that the Welding Power Source will

withstand short-term overload without adverse eects. The welding current range values should be used as a guide only. Current

delivered to the arc is dependent on the welding arc voltage, and as welding arc voltage varies between dierent classes of

electrodes, welding current at any one setting would vary according to the type of electrode in use. The operator should use the

welding current range values as a guide then ne tune the welding current to suit the application..

WARNING

Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary power

supply is switched o.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.

3.06 STICK (SMAW) Setup

200A

Set W

elding Current

as speciﬁed by th

Electrode Manufacturer

Set Process Selection

Switch to STICK.

Set ARC Force

Positive Output

Terminal

(Dinse™ 50)

Negative Output

Terminal

(Dinse™ 50)

Art#: A-09784

Figure 3-2: Setup for STICK (SMAW) Welding

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ESAB ET 201i DC Inverter Arc Welder User manual

Brand: ESAB

Model: ET 201i DC Inverter Arc Welder

Category: Welding System

Type: User manual

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ESAB ET 201i DC Inverter Arc Welder User manual

ESAB ET 201i DC Inverter Arc Welder User manual

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