ESAB Caddy® Arc 150i A34 User manual

Brand: ESAB

Model: Caddy® Arc 150i A34

Category: Welding System

Type: User manual

This manual is also suitable for

Caddy Arc 150i A34

Valid for serial no. 620--xxx--xxxx0459 263 101 GB 060523

Arc 150i

Caddyt A34

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 DIRECTIVE 3........................................................

2SAFETY 3...........................................................

3 INTRODUCTION 5...................................................

3.1 Equipment 5................................................................

4 TECHNICAL DATA 5.................................................

5 INSTALLATION 6....................................................

5.1 Placing 6...................................................................

5.2 Rating plate 6...............................................................

5.3 Mains power supply 6........................................................

6 OPERATION 7.......................................................

6.1 Connections and control devices 7............................................

6.2 Connection of welding and return cable 7.......................................

6.3 Control panel 7.............................................................

6.4 Settings 9..................................................................

6.5 Overheating protection 9.....................................................

6.6 MMA welding 9.............................................................

6.7 TIG welding 10...............................................................

6.8 Remote control unit 10........................................................

7 MAINTENANCE 11....................................................

7.1 Cleaning the dust filter 11.....................................................

8 FAULT TRACING 11...................................................

8.1 Fault codes 12...............................................................

9 ORDERING SPARE PARTS 12..........................................

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

ORDERING NUMBER 16.................................................

SPARE PARTS LIST 17...................................................

ACCESSORIES 18.......................................................

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1DIRECTIVE

DECLARATION OF CONFORMITY

ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that weld-

ing power source Arc 150i from serial number 620 complies with standard IEC/EN 60974--1, in ac-

cordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with stan-

dard IEC/EN 60974--10 in accordance with the requirements of directive (89/336/EEC) and adden-

dum (93/68/EEC).

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Kent Eimbrodt

Global Director Equipment and Automation

ESAB AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924

Laxå 2006--05--22

2SAFETY

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:

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.

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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.

WARNING!

Read and understand the instruction manual before installing

or operating.

Do not use the power source for thawing frozen pipes.

WARNING!

This product is solely intended for arc welding.

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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3 INTRODUCTION

The Arc 150i is a welding current power source intended for use with coated

electrodes (MMA welding) and TIG welding.

3.1 Equipment

The Arc 150i is supplied with 3 m of mains cable and an instruction manual.

ESAB’s accessories for the product can be found on page 18.

4 TECHNICAL DATA

Arc 150i

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 71--78 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 t o the time as a percentage of a t en--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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5 INSTALLATION

The installation must b e executed by a profession al.

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.

Note!

Connect the power source to the electricity mains with a network impedance of 0.210 ohm or lower. If the

network impedance is higher , there is a risk of flicker in the illuminators.

5.1 Placing

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

5.2 Rating plate

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

5.3 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 regards the mains cable area. A protective earth

connection must be made in accordance with regulations.

5.3.1 Recommend ed fuse sizes and minimum cable areas

Arc 150i

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 max. 16A.

North American version: The mains cable is approved for maximun 18 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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6 OPERATION

6.1 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

6.2 Connection of welding and return cable

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

nection of the welding and the return cable. Connect the welding cable to the pole indi-

cated 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.

6.3 Control panel A34

Welding process parameters are controlled via the control panel.

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6.3.1 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 --

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 --

6.3.2 Panel fu n ctio n symbols

MMA Amp/Volt Fjärrdon

TIG Hot Start Arc Force

6.3.3 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

F = setting regulator ArcPlust

Return by pressing ArcForce and HotStart simultaneously for 1

second.

cmha2p11

cmha2p10

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6.4 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%

6.5 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.

6.6 MMA weldin g

The Arc 150i gives direct current, and you can weld most metals to alloy and non--

alloy steel, stainless steel and cast iron. The Arc 150i 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 immedi -

ately m elts 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 completely.

If you are working on a welding bench, check before attempting

to strike the arc that residual waste metal, pieces of e lectrode 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, how-

ever, you have to use lateral movements.

Setting regulator -- ArcPlust

The Arc 150i 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 arc.

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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.

Current

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

workpiece.

The current set value can be changed irrespective of which m enu is displayed. This

value is displayed in the main menu only.

6.7 TIG welding

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

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

by shielding gas.

TIG welding is particularly useful when high quality standards are r equired and when

welding thin sheet. Arc 150i also has very good TIG welding characteristics.

Before using the Arc 150i for TIG welding it must be equipped with:

S a TIG torch and gas valve

S a cylinder of argon

S an argon regulator

S tungsten electrodes

S suitable filter metal, if necessary.

“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.

6.8 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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7 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.

7.1 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.

8 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 mains 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.

The thermal overload trips ope-

rate frequently.

S Check whether the thermal overload trips have operated

(indicated by the orange lamp on the front panel).

S Check the main power supply fuses.

The thermal overload trip opera-

tes 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 performance. 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.

S Check the main power supply fuses.

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8.1 Fault codes

The Arc 150i comes with built --in fault monitoring. If a fault occurs, a code is shown

in the display.

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

should b e sent to an authorised ESAB service workshop for repair.

Fau

Description Resetting Action

E1 Internal RAM fault Restart the machine.