ESAB CaddyArc 150 VRD User manual

Valid for serial no. 613--xxx--xxxx,0460 044 074 060326

Arc 150i VRD

Caddyt A34

Instruction manual

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Rights reserved to alter specifications without notice.

ENGLISH 3..............................................

ENGLISH

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TOCe

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

2 I NTRODUCTION 6...................................................

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

3 TECHNICAL DATA 6.................................................

4 INSTALLATION 7....................................................

4.1 Placing 7...................................................................

4.2 Rating plate 7...............................................................

4.3 Mains power supply 7........................................................

5 OPERATION 8.......................................................

5.1 Connections and control devices 8............................................

5.2 Connection of welding and return cable 8.......................................

5.3 Control panel 9.............................................................

5.4 Settings 10..................................................................

5.5 Overheating protection 10.....................................................

5.6 VRD functionality (Voltage Reduction Device) 11................................

5.7 MMA welding 12.............................................................

5.8 TIG welding 13...............................................................

5.9 Remote control unit 13........................................................

6 MAINTENANCE 14....................................................

6.1 Cleaning the dust filter 14.....................................................

7 FAULT TRACING 15...................................................

7.1 Fault codes 16...............................................................

8 ORDERING SPARE PARTS 16..........................................

DIAGRAM 18............................................................

ORDERING NUMBER 20.................................................

SPARE PARTS LIST 21...................................................

ACCESSORIES 22.......................................................

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1SAFETY

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 recommen-

dations 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

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 welding equipment must be familiar with:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding

2. The operator must ensure that:

S no unauthorized person is stationed within the working area of the equipment when it is

started up.

S no--one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose

S be free from drafts

4. Personal safety equipment

S Always wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.

S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.

S Work on high voltage equipment may only be carried out by a qualified electrician.

S Appropriate fire extinquishing equipment must be clearly marked and close at hand.

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic

Equipment and its implementation 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 our local representative.

By applying this European Directive you will improve the environment and human health!

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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 PRECAU-

TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE

BASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can kill

S Install and earth the welding unit in accordance with applicable standards.

S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

S Insulate yourself from earth and the workpiece.

S Ensure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

S Keep your head out of the fumes.

S 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.

S Protect y our eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearing

S Protect y our ears. Use earmuffs or other hearing protection.

S Warn bystanders of the risk.

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

PROTECT YOURSELF AND OTHERS!

ESAB can p rovide you with all necessary welding protection and accessories.

Do not use the power source for thawing frozen pipes.

WARNING!

This product is solely intended for arc welding.

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2 INTRODUCTION

The CaddytArc 150i VRD is a welding current power source intended for use with

coated electrodes (MMA welding) and TIG welding.

2.1 Equipment

The Caddyt Arc 150i VRD is supplied with 3 m of mains cable and an instruction

manual.

ESAB’s accessories for the product can be found on page 22.

3 TECHNICAL DATA

Caddyt Arc 150i VRD

Mains voltage 230 V, 1 µ 50/60 Hz

Fuse (delayed--action) 16 A

Primary current I

max

36 A

Primary current I

eff

21 A

Voltage/current range (DC) 4 A /20 V -- 150 A /26 V

Maximum permissible load at

25% duty cycle

35% duty cycle

60% duty cycle

100% duty cycle

150 A / 26 V

140 A / 26 V

110A/25V

90 A / 24 V

Power factor at maximum current 0,62

Efficiency at maximum current 77%

Open --circuit voltage 30 V

Operating temperature -- 1 0 ˚C-- +40˚ C

Constant A--weighed sound pressure <70db

Dimensions, l x b x h 394 x 267 x 274 mm

Weight 9kg

Enclosure class IP 23C

Application class

Duty cycle

The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-

tain load without overloading.

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 b e executed by a profession al.

WARNING!

Read and understand the instruction manual before installing

or operating.

WARNING!

This product is intended for industrial use. In a domestic environment this product may cause radio

interference. It is the user’ s responsibility to take adequate precautions.

4.1 Placing

Place the power source so that its cooling air inlets and outlets are not obstructed.

4.2 Rating plate

The rating plate is located on the underside of the power source.

4.3 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 standards for the country in

question must be complied with as r egards the mains cable area. A protective earth

connection must be made in accordance with r egulations.

4.3.1 Recommend ed fuse sizes and minimum cable a reas

Caddyt Arc 150i VRD

Mains voltage

230 V ¦10 %, 1--phase

Mains frequency 50--60 Hz

Fuse (delayed--action)

100A 20% duty cycle

120A 35% duty cycle

150A 35% duty cycle

10 A

16 A

20 A*)

Mains cable, area 3x2.5mm

Welding cable, area 16 mm

*) Note! The installed plug is approved for maximum 15A.

Note! Th e 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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5OPERATION

Connect the power source to the electricity mains with a network impedance of 210 ohm

or lower. If the network impedance is higher, ther e is a risk of flicker in the illuminators.

5.1 Connections and control devices

1 Main power supply switch, 0 / 1 4 Connection for remote control

2 Mains cable 5 Welding cable connector (+)

3 Connection for return cable (--) 6 Control panel (see 6.2)

3 and 5 are used for welding current supply and return cable connection during MMA

welding

5.2 Connection of welding and return cable

The welding power source has two terminals, one plus and one minus pole, for the

connection of the welding and the return cable. Connect the welding cable to the

pole indicated on the package of the electrode to be used.

Connect the return cable to the other terminal. Fit the earth clamp of the return cable

to the work--piece and make sure there is good contact between the work--piece and

the return cable terminal on the welding power source.

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5.3 Control panel

Welding process parameters are controlled via the control panel.

5.3.1 Functional d escription

Pos Symbol/Function Set values

1 Knob for setting data --

2 Arc Force 0 -- 99%

3 Hot Start 0 -- 99%

4 TIG welding “Live TIG--start” --

5 MMA welding with coated electrodes -- Light on VRD active --

6 Pushbutton indicating welding current (A) and/or arc voltage (V) --

7 Connection of remote control unit --

8 Indicating lamp (green), mains power supply --

9 Indicating lamp (yellow) for overheating --

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5.3.2 Panel fu n ctio n symbols

MMA Amp/Volt Fjärrdon

TIG Hot Start Arc Force

5.3.3 Hidden functions

A number of setting options for welding data, such as drop welding and ArcPlust,

are obtained by pressing Arc Force and Hot Start simultaneously

for at least 1 second. The function is selected using the setting knob, and the

welding method is selected by pressing the ArcForce or HotStart button.

The following welding data setting options for MMA can be found under the letters:

D = setting Drop welding Off=0 or On =1

F = setting regulator ArcPlust Off=1 or On =0

Return by pressing ArcForce and HotStart simultaneously for 1

second.

5.4 Settings

Settings Setting range In steps of: Default value

Arc Force 0 -- 99% 1% 5%

Drop welding I/0 -- 0

Regulator ArcPlust I/0 -- 1

Hot Start 0 -- 99% 1% 0%

5.5 Overheating protection

The welding power source has a thermal protection 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 protection resets automatically

when the temperature has fallen.

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5.6 VRD functionality (Voltage Reduction Device)

The main task for the VRD function (VRD = voltage reduction device) is to

secure that the open--circuit voltage doesn’t exceed the specified voltage limit

when welding is inactive.

Normally it shouldn’t be possible to occur since hardware functionality for

open--circuit voltage reduction is enabled when not welding. T he enable/disable

of the arc voltage reduction function is controlled through software. Arc voltage

reduction is disabled when the syst em consider welding is active.

If some problem occurs with the voltage reduction function and the arc voltage

exceeds the specified limit, functionality in software detects that and indicates it

to the user. Indication is done by presenting error 16 from unit 2 in the display.

This error can not be cleared out by the user and it will be visible in the display

until the power source is powered off. It is not possible to start a new weld when

the error is active.

To indicate that VRD is active or inactive the MMA lamp on the panel will be

used according to:

S MMA lamp is on if method MMA is selected, welding is inactive and arc

voltage is under specified limit.

S MMA lamp is off during MMA welding or error 16 is active.

Knowledge about welding active or inactive is based on the arc on/off message

from the power source.

Normal open--circuit voltage is about 20 V and the limit for error indication is set

to 35 V. Supervision of the open--circuit voltage is activated 750 ms after

enabling of the arc voltage reduction function.

cmha2p11

cmha2p10

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5.7 MMA weldin g

The Caddyt Arc 150i VRD gives direct current, and you can weld most metals to

alloy and non--alloy steel, stainless steel and cast iron.T he Caddyt Arc 150i VRD

allows you to weld most coated electrodes from ∅ 1.6 to ∅ 3.25.

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 im-

mediately 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 m atch.

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 attempt-

ing to strike the arc that residual waste metal, pieces of elec-

trode or other objects 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, however, you have to use lateral movements.

Setting regulator -- ArcPlust

The Caddyt Arc 150i VRD is supplied with ArcPlust, a new type of control that,

during MMA welding, produces a more intensive, more concentrated and calmer arc.

It recovers more quickly after a drop short--circuit, which reduces the risk of the

electrode becoming stuck.

Drop welding (MMA)

Drop welding can be used when welding with stainless electrodes.

This technique involves alternately striking and extinguishing the arc in order to

achieve better control of the supply of heat. The electrode needs only to be raised

slightly to extinguish the a rc.

Hot Start

Hot start increases the weld current for an adjustable time at the start of welding,

thus reducing the risk of poor fusion at the beginning of the joint.

Arc Force

The arc force is important in determining how the current changes in response to a

change in the arc length. A lower value gives a calmer arc with less spatter.

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Current

A higher current produces a wider weld pool, with better penetration into the

workpiece.

The current set value can b e changed irrespective of which menu is displayed. T his

value is displayed in the main menu only.

5.8 TIG welding

TIG welding melts the metal of the workpiece, using an arc struck from a tungsten

electrode, which does not melt itself. The weld pool and the electrode are protected

by shielding gas.

TIG welding is particularly useful when high quality standards are required and when

welding thin sheet. Caddyt also has very good T IG welding characteristics.

Before using the Caddyt for TIG welding it must be equipped with a T IG torch and

gas valve, a cylinder of argon, an argon regulator, tungsten electrodes and, if

necessary, suitable filter metal.

“Live Tig--start“

The Live Tig--start“ function strikes the arc when the electrode is brought into contact

with the workpiece and then lifted away from it.

5.9 Remote control unit

The remote control unit has to be connected to the remote control unit socket on the

power source.

If the remote control unit is not to be used, this function is removed from the panel.

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6 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Note!

All guarantee undertakings from the supplier cease to apply if the customer himself

attempts any work in the product during the guarantee period in order to rectify any

faults.

6.1 Cleaning the dust filter

S Remove the fan grille: see sketch.

S Release the dust filter

S Blow the filter clean with compressed air (reduced pressure).

S Ensure that the filter with the finest mesh is placed towards the grille.

S Replace the fan grille with the dust filter.

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7 FAULT TRACING

Try these recommended checks and inspections before sending for an authorised

service technician.

Type of fault Action

No arc. S Check that the m ains power supply switch is

turned on.

S Check that the welding current supply and return

cables are correctly connected.

S Check that the correct current value is set.

S Check to see whether the MCB has tripped.

S Check the main power supply fuses.

The thermal protection

operates frequently.

S Check to see whether the dust filter is clogged.

S Make sure that you are not exceeding the rated

data for the power source (i.e. that the unit is not

being overloaded).

Poor welding perform--

ance.

S Check that the welding current supply and return

cables are correctly connected.

S Check that the correct current value is set.

S Check that the correct electrodes are being used.

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7.1 Fault codes

The Caddyt Arc 150i VRD comes with built--in fault m onitoring. If a fault occurs, a

code is shown in the display.

If any of these fault codes is displayed permanently or recurs often, the m achine

should be sent to an authorised ESAB service workshop for repair.

Fault Description Action Resetting

E1 Internal RAM fault Restart the power source.