ESAB Heliarc 283i AC/DC User manual

Instruction manual

0463 369 001 GB 20160105 Valid for: 283i=S2733450468 353i=S2733450508

Coolingunit=S2733450427

Heliarc283iAC/DC

Heliarc353iAC/DC

Heliarccoolingunit

TABLE OF CONTENTS

0463 369 001 © ESAB AB 2016

1 SAFETY ................................................................................................................ 5

2 INTRODUCTION................................................................................................... 7

2.1 Overview ............................................................................................................... 7

2.2 Equipment............................................................................................................. 7

3 TECHNICAL DATA ............................................................................................... 8

4 INSTALLATION................................................................................................... 10

4.1 General................................................................................................................ 10

4.2 Lifting instructions............................................................................................. 10

4.3 Location .............................................................................................................. 10

4.4 Mains supply ...................................................................................................... 11

5 OPERATION ....................................................................................................... 13

5.1 Overview ............................................................................................................. 13

5.2 Connections and control devices power source ............................................13

5.3 Quick set up........................................................................................................ 16

5.3.1 Operation mode selection ................................................................................ 16

5.3.2 Stick (SMAW) mode ......................................................................................... 16

5.3.3 TIG (GTAW) two stroke mode with remote switch ........................................... 17

5.3.4 TIG (GTAW) two stroke mode with foot control................................................ 17

5.3.5 TIG (GTAW) four stroke mode ......................................................................... 17

5.3.6 TIG (GTAW) spot mode.................................................................................... 18

5.3.7 AC mode .......................................................................................................... 18

5.3.8 Pulse mode - Peak/Background.......................................................................19

5.3.9 Pulse mode - Frequency/Duty cycle ................................................................19

5.3.10 Store and recall programs................................................................................20

5.3.11 General functions ............................................................................................. 21

5.3.12 Remote control - On/Off/Minimum ................................................................... 21

5.4 Sub menu power source ...................................................................................21

5.5 Main functions power source ...........................................................................22

5.6 TIG welding information ....................................................................................24

5.7 Power source overheated .................................................................................25

5.8 Connections and control devices cooling unit ...............................................25

5.9 Starting up the cooling unit .............................................................................. 26

6 MAINTENANCE.................................................................................................. 28

6.1 Overview ............................................................................................................. 28

6.2 Power source...................................................................................................... 28

6.3 Welding torch ..................................................................................................... 28

6.4 Cooling unit ........................................................................................................ 28

6.5 Fill up the cooling unit with coolant.................................................................29

7 FAULT TRACING................................................................................................ 30

TABLE OF CONTENTS

0463 369 001 © ESAB AB 2016

8 ORDERING SPARE PARTS ............................................................................... 32

DIAGRAM ..................................................................................................................33

WELDING TABLES ...................................................................................................35

ORDERING NUMBERS.............................................................................................37

ACCESSORIES .........................................................................................................38

Rights reserved to alter specifications without notice.

1 SAFETY

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1 SAFETY

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety

precautions must meet the requirements that apply to this type of equipment. The following

recommendations should be observed in addition to the standard regulations that apply to

the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the

equipment. Incorrect operation of the equipment may lead to hazardous situations which can

result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

○ its operation

○ location of emergency stops

○ its function

○ relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorised person is stationed within the working area of the equipment when it

is started up

○ no-one is unprotected when the arc is struck or work is started with the equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

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

become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

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

○ Appropriate fire extinguishing equipment must be clearly marked and close at hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

1 SAFETY

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WARNING!

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 the 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 screen and filter lens and

wear protective clothing

• Protect bystanders with suitable screens or curtains

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure therefore that there are no

inflammable materials nearby

NOISE - Excessive noise can damage hearing

• Protect your ears. Use earmuffs 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!

Do not use the power source for thawing frozen pipes.

CAUTION!

Read and understand the instruction manual before

installing or operating.

CAUTION!

Class A equipment is not intended for use in residential

locations where the electrical power is provided by the

public low-voltage supply system. There may be potential

difficulties in ensuring electromagnetic compatibility of

class A equipment in those locations, due to conducted

as well as radiated disturbances.

2 INTRODUCTION

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2 INTRODUCTION

2.1 Overview

The Heliarc 283i and 353i AC/DC are welding power sources intended for MMA and TIG

welding. The Heliarc 283i is rated up to 280 A and the Heliarc 353i up to 350 A.

A 230 V AC auxiliary supply is available, accessed through the rear panel, when using the

Heliarc cooling unit.

The Heliarc cooling unit is used with the Heliarc 283i and 353i AC/DC. It distributes 2

litres/min, with the torch connected, with a power of 60 W.

A trolley is an option available for the power sources.

ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of

this manual.

2.2 Equipment

The power sources comes with:

• return cable with clamp

• mains cable

• gas hose

• instruction manual

The cooling unit comes with:

• instruction manual

3 TECHNICAL DATA

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3 TECHNICAL DATA

283i AC/DC 353i AC/DC

Mains voltage 400 V ±10%,

3~ 50/60 Hz

400 V ±10%,

3~ 50/60 Hz

Mains cable 4G4 mm 4G4 mm

Line fuse min 25 A min 25 A

Setting range GTAW/TIG AC/DC 4 - 280 A 4 - 350 A

Maximum output

GTAW/TIG, AC/DC 280 A at 100% 350 A at 45%

Gas pre-flow 0.5 - 30 sec 0.5 - 30 sec

Slope up/slope down 0.1 - 10 sec 0.1 - 10 sec

Gas post-flow 0.5 - 30 sec 0.5 - 30 sec

Frequency AC 20 -200 Hz 20 - 200 Hz

AC balance 10 - 90% 10 - 90%

DC Pulse mode frequency 0.4 - 300 Hz 0.4 - 300 Hz

AC Pulse mode frequency 0.4 - 2 Hz 0.4 - 2 Hz

Pulse duty (pulse

time/background time) 30 - 65% 30 - 65%

Background current 10 - 90 A 10 - 90 A

Slope down time 0.1 -10 s 0.1 - 10 s

Start/crater current (4-stroke) 10 - 90 % 10 - 90 %

Post purge time 0.5 - 30 s 0.5 - 30 s

Remote start point current 4 - 100 A 4 - 100 A

Open circuit voltage max 68 V 68 V

Power factor at 100 % TIG mode 0.75 0.8

Setting range SMAW/MMA 4 - 280 A 4 - 350 A

Maximum output SMAW/MMA, AC/DC

20% duty cycle - 350 A

40% duty cycle 280 A -

KVA GTAW/TIG 11 14.5

KVA SMAW/MMA 14.2 19

Enclosure class IP 21S IP 21S

Dimensions l × w × h 600 × 300 × 620 mm 600 × 300 × 620 mm

Weight without cooling unit 50 kg 50 kg

Weight trolley 35 kg 35 kg

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration

by solid objects or water.

Equipment marked IP21 is intended for indoor use.

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3 TECHNICAL DATA

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Heliarc cooling unit

Mains voltage 400 V ±10%, 1~, 50/60 Hz

Maximum power supply current 0.75 A

P

1

l/min 0.5 kW

Cooling power 60 W

Coolant "ESAB's ready mixed coolant, see the

"ACCESSORIES" chapter.

Coolant quantity 5 l (delivered with approx. 2.5 l)

Pressure max 0.35 MPa

Maximum water flow 2.0 l/min

Operating temperature -10° to +40°C

Transportation temperature -20° to +55°C

Dimensions (l × w × h) 475 × 310 × 250 mm

Weight empty 14 kg

Enclosure class IP21

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration

by solid objects or water.

Equipment marked IP21 is intended for indoor use.

4 INSTALLATION

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4 INSTALLATION

4.1 General

The installation must be carried out by a professional.

4.2 Lifting instructions

Lifting the power source by hand.

WARNING!

The power source weighs 50 kg (110 lbs).

WARNING!

Be two persons and lift the power

source by using the two handles.

Lifting the power source using hoist and strap.

WARNING!

Lift the power source by using the

eyebolt. Keep the power supply

as horizontal as possible.

WARNING!

Secure the equipment -

particularly if the ground is

uneven or sloping.

4.3 Location

Position the welding power source such that its cooling air inlets and outlets are not

obstructed. Make sure that no deposits or dust goes into the power source. Prevent impacts,

rubbing and exposure to dripping water, excessive heat sources or any unusual situations.

4 INSTALLATION

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4.4 Mains supply

NOTE!

Mains supply requirements

This equipment complies with IEC 61000-3-12 provided that the short-circuit

power is greater than or equal to S

scmin

at the interface point between the user's

supply and the public system. It is the responsibility of the installer or user of the

equipment to ensure, by consultation with the distribution network operator if

necessary, that the equipment is connected only to a supply with a short-circuit

power greater than or equal to S

scmin

. Refer to the technical data in the

TECHNICAL DATA chapter.

CAUTION!

Make sure that the ON/OFF switch is set to OFF (0) before making any electrical

connections between the power source and the 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 mains distribution panel must comply with the

regulations in force in the country of use. The mains supply system must be of the industrial

type.

A protective earth connection must be made in accordance with regulations. The power

source must be correctly connected to earth to protect the operator. It is indispensable to

provide good earthing by means of the yellow-green lead in the power cable, to prevent

discharges due to accidental contacts with earthed objects. The chassis, which is conductive,

is electrically connected with the earth lead. If the equipment is not correct connected with

the earth lead it may cause electric shocks which are dangerous for the operator.

The power source works at mains voltages differing by 20% from the rated mains (400 V

rated, minimum voltage 320 V, maximum voltage 480 V).

Heliarc 283i AC/DC Heliarc 353i AC/DC

Mains voltage 400 V, 3~ , 50/60 Hz 400 V, 3~ , 50/60 Hz

Fuse 20 A 25 A

Connection instruction cooling unit

Make sure that the Heliarc is correctly connected to earth to protect the operator. It is

indispensable to provide good earthing by means of the yellow-green lead in the power

cable, to prevent discharges due to accidental contacts with earthed objects.

The chassis, which is conductive, is electrically connected with the earth lead. If the

equipment is not correct connected with the earth lead it may cause electric shocks which

are dangerous for the operator.

The cooling unit must be connected to the power source with the special ILME multipole plug

supplied. Make sure that the power source is turned off and disconnected from the mains

power supply before making any electrical connections between the cooling unit and the

power source.

If the cooling unit is going to be connected to three phase mains voltage, replace the special

ILME 4-way plug with a three phase plug. Connect the supply wires to only two of the

contacts (black-brown) of the plug and the earth led (yellow/green) to the earth contact.

4 INSTALLATION

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Connect the cooling unit to the power source

1. Remove the screws (1), the safety bolt (2) and the door panel (3).

2. Remove the plastic cap at the rear of the trolley chassi.

3. Pull the cooling unit input cable through the hole at the rear of the trolley chassi.

4. Fasten the input cable with the screws (4).

The Heliarc 353i AC/DC is already equipped with a connector to connect the cooling unit. To

start the cooling unit it is necessary to switch on both the power source and the cooling unit.

Hydraulic connection

Connect the water delivery pipe of the torch to water output coupling on the cooling unit.

Connect the water return pipe of the torch to the water input coupling on the cooling unit.

5 OPERATION

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5 OPERATION

5.1 Overview

General safety regulations for handling the equipment can be found in the "SAFETY"

chapter of this manual. Read it through before you start using the equipment!

5.2 Connections and control devices power source

Front connections

Type Connection PIN Description

TIG

YES A Gas

TIG TORCH B Negative

YES D-F Pin

EARTH CLAMP E Positive

Type Connection PIN Description

MMA

NO A Gas

EARTH CLAMP B Negative

POSSIBLE REMOTE F Pin

ELECTRODE E Positive

NOTE!

Connection D, 2 pin cannon, can be used for either analogue foot control or

torch.

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5 OPERATION

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Cooling unit connection

4 Pin

connector

PIN Description

Power supply

1 Power supply common

2 Power supply 115/230 V AC

3 Power supply 400 V AC

GRD 4 Chassis common

14 pin connector

14 Pin

connector

PIN Description

Torch trigger

A Torch switch

B Torch switch

Remote control

E Remote control circuit common

F +5 V DC input remote control

G +5 V DC output remote control

D +5 V DC output remote control

GRD H Chassis common

2 pin connector

2 Pin

connector

PIN Description

Torch trigger

A Torch switch

B Torch switch

5 OPERATION

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Front panel

Item Denomination

1 Power source live LED

2 Welding enabled LED

3 Over temperature LED

4 Volt display

5 Ampere display

6 AC mode button

7 AC mode LED

8 AC frequency setting, 20-200 Hz

9 AC balance setting, 10-90%

10 Pulse mode button (0.4-300 Hz DC, 0.4-2 Hz AC)

11 Pulse mode LED

12 Pre-gas (0.1-2.5 sec) Post-gas (0.1-30 sec) button

13 Base current button (10-90%)

14 Slope up/down button (slope up 0.1-10 sec, slope down 0.1-10 sec)

15 Encoder knob for current setting and other settings

16 HF LED

17 HF button

18 Select mode button

19 Remote control button

20 Remote button LED

21 Mode TIG dual schedule LED

22 Mode TIG spot LED

23 Mode TIG 4 stroke LED

5 OPERATION

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Item Denomination

24 Mode TIG 2 stroke LED

25 Mode Stick LED

5.3 Quick set up

5.3.1 Operation mode selection

Press the select mode button (1) repeatedly until the desired mode is selected, indicated by

a green LED.

5.3.2 Stick (SMAW) mode

1. Press the select mode button (1) repeatedly until the Stick w/Hot start & Arc force LED is

lit.

2. Press the select mode button (1) for a few seconds until "HS" is shown in the V display.

3. Set the value for hot start with the encoder knob (2).

4. Press the select mode button (1) for a few seconds unit "HS" is shown in the V display.

5. Press the select mode button (1) again, "AF" is shown on the V display.

6. Set the value for the arc force with the encoder knob (2).

5 OPERATION

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5.3.3 TIG (GTAW) two stroke mode with remote switch

1. Press the select mode button (1) repeatedly until the TIG two stroke LED is lit.

2. Press the slope up/down button (3) and adjust the slope down time.

5.3.4 TIG (GTAW) two stroke mode with foot control

1. Press the select mode button (1) repeatedly until the TIG two stroke LED is lit.

2. Press the slope up/down button (3) and adjust the slope down time with the encoder

knob (2) to the minimum time.

5.3.5 TIG (GTAW) four stroke mode

5 OPERATION

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1. Press the select mode button (1) repeatedly until the TIG four stroke LED is lit.

2. Press the slope up/down button (3) once to adjust the down slope (ds displayed in V

window). Press the slope up/down button (3) twice to adjust the up slope (us displayed in

V window). Use the enconder knob (2) to adjust the slope time, 0.1 to 10 seconds.

3. Press the base current button (4) and adjust the current level (10-90% of main amps)

with the encoder knob (2).

5.3.6 TIG (GTAW) spot mode

1. Press the select mode button (1) repeatedly until the TIG Spot mode LED is lit.

2. Adjust the spot time, shown in A display, with the encoder knob (2).

3. Set the spot welding current level in Normal TIG mode.

4. Press the select mode button (1) repeatedly until the TIG Spot mode LED is lit.

5.3.7 AC mode

1. Press the AC mode button (1) to turn on the AC mode.

2. Adjust the spot time, shown in A display, with the AC frequency button (2).

3. Adjust the balance (10 to 90%) with the AC balance button (3).

4. Press the AC mode button (1) for 3 seconds to turn off the AC mode.

5 OPERATION

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5.3.8 Pulse mode - Peak/Background

1. Press the pulse mode button (1) to turn on the pulse mode.

2. Adjust the peak current level with the encoder knob (2).

3. Adjust the background current level with the base current button (3).

5.3.9 Pulse mode - Frequency/Duty cycle

1. With the pulse mode ON, press the pulse mode button (1) to switch between "FRE"

(frequency) and "DUT" (duty).

2. In "FRE" mode adjust the pulse frequency (AC: 0.4 to 2 Hz, DC: 0.4 to 300 Hz) with the

encoder knob (2).

3. In "DUT" mode adjust the duty (30 to 65% peak width) with encoder knob (2). More duty

= more heat.

4. Press the pulse mode button (1) for 3 seconds to turn off the pulse mode.

5 OPERATION

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Ampere

t

A = Base current time

B = Pulse time

C = Frequency

The duty is B divided by A in percent.

5.3.10 Store and recall programs

60 welding parameters can be stored and recalled.

1. Press both the pulse mode button and pre-gas/post-gas button (1) for 3 seconds. "Prg"

and a program number is shown on the display.

2. Select program number with the encoder knob (2).

3. To store, press the base current button (3) for 3 seconds. The unit beeps 4 times when

the program is stored.

4. To recall, press the slope up/slop down button (4) for 3 seconds. The unit display flashes

when the program is recalled.

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ESAB Heliarc 283i AC/DC, 353i AC/DC, Heliarc 283i AC/DC, 353i AC/DC, Heliarc Cooling Unit, Heliarc Cooling Unit User manual

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