ESAB Caddy® Arc 150i A34 User manual

Category
Welding System
Type
User manual

This manual is also suitable for

GB
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).
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------
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.
GB
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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
2
Welding cable, area 16 mm
2
*) 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.
GB
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
lt
Description Resetting Action
E1 Internal RAM fault Restart the machine.
If the fault persists, contact a
service workshop
E2 External RAM fault Restart the machine.
If the fault persists, contact a
service workshop
E3 EPROM f ault Restart the machine.
If the fault persists, contact a
service workshop
E4 Fault in RAM with battery
backup
Restart the machine.
If the fault persists, contact a
service workshop
E5 Memory error, variable value
outside limits
Restart the machine.
If the fault persists, contact a
service workshop
E6 Low battery voltage Reset by pressing a button If the fault persists, contact a
service workshop
E10 + 20V fault
(18.5 21.5 V)
Automatic reset once fault
has disappeared
E11 --15 V fault
(--13.0 -- --16.0)
Automatic reset once fault
has disappeared
E13 High temperature Automatic reset once fault
has disappeared
E14 Current servo fault Automatic reset once fault
has disappeared Also reset
by pressing a button
E99 Bridging fault The digital control card is
bridged in a non--defined
combination.
Switch off the machine. If the
fault persists, contact the ser-
vice workshop.
9 ORDERING SPARE PARTS
Arc150i is designed and tested in accordance with the international and European
standards IEC/EN 60974--1 and EN 60974--10. It is the obligation of the service unit
which has carried out the service or repair work to make sure that the product still
conforms to the said standard.
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
GB
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p
Diagram
-- 1 4 --
CaddyArc150
-- 1 5 --
CaddyArc150
Arc 150i
Edition 060523
Ordering number
-- 1 6 --
bh26o
Ordering no. Denomination Type
0459 199 880 Welding Power source CaddytArc 150i, A34 for 230 V mains voltage
0459 199 886 Welding Power source CaddytArc 150i, A34 for 230 V mains voltage,
North American version
0459 263 990 Spare parts list CaddytArc 150i
Arc 150i
Edition 060523
Spare parts list
-- 1 7 --
bh26s
Item
Qty Ordering no. Denomination
101 1 0459 277 001 Filter
R0459 263 /E060523/P18
Arc 150i
Accessories
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bh26a
MMA welding and return cable kit .......
(”crocodile” type holder)
0349 501 078
MMA welding and return cable kit ........
(”screwe” type holder)
0349 501 079
Remote control MMA 1 (10mcable).......
MMA and TIG: current
0349 501 024
Foot control FS002 ......................
MMA and TIG current
0349 090 886
Remote control unit AT1 .................
MMA and TIG: current
0459 491 896
Remote control unit AT1 CF .............
MMA and TIG: rough and fine setting of
current.
0459 491 897
Remote cable 12 pole -- 8 pole
5m.....................................
10m....................................
15m....................................
25m....................................
0459 552 880
0459 552 881
0459 552 882
0459 552 883
Shoulderstrap .......................... 0459 367 880
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p
ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.co m
060517
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Prague
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel:+4536300111
Fax:+4536304003
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel:+33130755500
Fax:+33130755524
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel:+3612044182
Fax:+3612044186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:+3902979681
Fax:+390297289181
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: +31 30 2485 377
Fax: +31 30 2485 260
NORWAY
AS ESAB
Larvik
Tel:+4733121000
Fax:+4733115203
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel:+421744882426
Fax:+421744888741
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel:+4631509500
Fax:+4631509222
ESAB international AB
Gothenburg
Tel:+4631509000
Fax:+4631509360
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem--MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 5308 9922
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 3 5296 7371
Fax:+81352968080
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 8027 9869
Fax:+60380274754
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel:+6568614322
Fax: +65 6861 31 95
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA
LLC ESAB
Moscow
Tel: +7 095 543 9281
Fax: +7 095 543 9280
LLC ESAB
St Petersburg
Tel: +7 812 336 7080
Fax: +7 812 336 7060
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.co m
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ESAB Caddy® Arc 150i A34 User manual

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Welding System
Type
User manual
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