ESAB Arc 151i A33 Instruction manual

Caddy

Arc 151i VRD

GB Instruction manual

Valid for serial no. 828-xxx-xxxx0460 825 274 GB 20130228

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

4.1 Location 8. . . . ... ... ..... ..... ....... ... ... ... ....... ... ... . . ... ... ... . . ....

lortnoc dna snoitcennoC2.5 . . ... ... ... ... ... ... ....... ... ... ... ....... .

5.5 MMA welding 10. . ... . . .... ... . ... ... ..... . .... . . . . . . . . . . . . .... . . . . . . .... . . . .

5.6 TIG welding 11. . . . ... ... ....... ... ....... ... ... ... ....... ... ... . . ... ... ... . . .

7.1 Fault codes 12. . . . ... ... ..... . ... ... ... ... ....... ... ... ... ....... ... ... ... . . .

4YTEFAS1 ...... .....................................................

6NOITCUDORTNI2 ...... .............................................

7ATAD LACINHCET3 ...... ...........................................

8NOITALLATSNI4 ...... ..............................................

8ylppus rewop sniaM2.4 . . . . ... ... . . . ... ... ... ... ... ....... ... ... ... ....... ... . .

9aera elbac muminim dna sezis esuf dednemmoceR1.2.4 . . ... .... . . . . ... ... ... .

9NOITAREPO5 ...... .................................................

9noitcerroc rotcaf rewoP - CFP1.5 . . ... ... ... ... ... ... ....... ... ... ... ....... ... .

9secived

01elbac nruter dna gnidlew fo noitcennoC3.5 . . ... ... ... ... ... ... ....... ... ... ... ...

01noitcetorp gnitaehrevO4.5 . . . . ... . ... ... ... ... ....... ... ... ... ....... ... ... . . . .

11tinu lortnoc etomeR7.5 . . . . ... ... . . . ... ... ... ... ... ....... ... ... ... ....... ... . .

11ECNANETNIAM6 ...... ..............................................

21gninaelc dna noitcepsnI1.6 . . ..... ... . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . . . ....

21GNICART-TLUAF7 ...... ............................................

31STRAP ERAPS GNIREDRO8 . ........................................

31GNIPPARCS DNA GNILTNAMSID9 ................................. . .

41MARGAID ................. ................ ...........................

61REBMUN REDRO ................................. ....................

71SEIROSSECCA ................................. ......................

Rights reserved to alter specifications without notice.

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1 SAFETY

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

place.

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:

2. The operator must ensure that:

3. The workplace must:

4. Personal safety equipment

5. General precautions

its operation location of emergency stops its function relevant safety precautions welding

no unauthorized person is stationed within the working area of the equipment when it is started up. no-one is unprotected when the arc is struck

be suitable for the purpose be free from drafts

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.

Make sure the return cable is connected securely. Work on high voltage equipment may only be carried out by a qualied electrician. Appropriate fire extinquishing equipment must be clearly marked and close at hand.

CAUTION

This product is solely intended for arc welding.

WARNING

Do not use the power source for thawing frozen pipes.

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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!

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 diculties in ensuring electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.

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

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2 INTRODUCTION

Arc 151i is a welding current power source intended for use with coated electrodes

(MMA welding) and TIG welding.

ESAB's accessories for the product can be found on page 17.

2.1 Equipment

Arc 151i is supplied with a 3 m welding cable, return cable, 3 m mains cable and an

instruction manual for power source and control panel.

Control panel A33

Welding process parameters are controlled via the control panel.

NOTE! See the separate instruction manual for a detailed description of the control panel.

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3 TECHNICAL DATA

Arc 151i

Mains voltage 230 V, 1 50/60 Hz

Primary current

I

TIG

max

I

MMA

max

Mains supply Z No-load power 30 W Setting range, MMA 4 A - 150 A

Setting range, TIG 3 - 150 A Permissible load at MMA

25% duty cycle 60% duty cycle 100% duty cycle

Permissible load at TIG

20% duty cycle 25% duty cycle 60% duty cycle 100% duty cycle

Power factor at maximum current

MMA TIG

Eciency at maximum current

MMA TIG

Open-circuit voltage MMA/TIG

with VRD

Operating temperature -10° C - +40° C Transportation temperature -20° C - +55° C Constant A-weighted sound pressure < 70 dB

Dimensions, l x b x h 418 x 188 x 208 mm Weight 8.1 kg Enclosure class IP 23 Application class

14 A 22 A

0.35 ohm

max

150 A / 26.0 V 100 A / 24.0 V 90 A / 23.6 V

150 A / 16.0 V 120 A / 14.8 V 110 A / 14.4 V

0.99

0.98

80% 77%

55 - 60 V < 35 V

Mains supply, Z

Maximum permissible line impedance of the network in accordance with IEC 61000-3-11.

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at a certain load without overloading. The duty cycle is valid for 40° C.

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.

max

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4 INSTALLATION

The installation must be carried out by a professional.

Note

Mains supply requirements

High power equipment may, due to the primary current drawn from the mains supply, influence the power quality of the grid. Therefore connection restrictions or requirements regarding the maximum permissible mains impedance or the required minimum supply capacity at the interface point to the public grid may apply for some types of equipment (see technical data). In this case 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 may be connected.

4.1 Location

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

4.2 Mains power supply

Check that the welding power source is connected to the correct voltage and that the correct fuse size is used. A protective earth connection must be made in accordance with regulations

Location of rating plate

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4.2.1 Recommended fuse sizes and minimum cable area

Arc 151i

Mains voltage

Mains frequency 50-60 Hz

Mains cable, area 3G2.5 mm

Phase current I

Welding cable, area 16 mm

Fuse

anti-surge type C MCB

1eff

230 V 10 %, 1-phase

2

11 A

2

16 A 13 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.

5 OPERATION

5.1 PFC - Power factor correction

The Arc 151i is a 230 V single-phase power sources equipped with a PFC circuit making it possible to use the full range of the machine on a 16 A fuse. The PFC also protects the machines against fluctuating mains voltage and makes it safer to use with a generator. The power source can operate with extra long mains cables, over 100 m, giving you a very larger working radius.

5.2 Connections and control devices

1 Connection (+)

MMA: for return cable or welding cable TIG: for return cable

2 Connection for remote control unit 5 Toggle switch for mains power supply 0 / 1

3 Control panel 6 Mains cable

4 Connection (+)

MMA: for return cable or welding cable TIG: for Tig torch l

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5.3 Connection of welding and return cable

The power source has two outputs, a positive terminal (+) and a negative terminal (-), for connecting welding and return cables. The output to which the welding cable is connected depends on the type of electrode used. The connecting polarity is stated on the electrode packaging. Connect the welding cable to the terminal stated on the electrode packaging.

Connect the return cable to the other output on the power source. Secure the return cable's contact clamp to the work piece and ensure that there is good contact between the work piece and the output for the return cable on the power source.

5.4 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.

5.5 MMA welding

Arc 151i gives direct current, and you can weld most metals to alloy and non-alloy

steel, stainless steel and cast iron. The power source allows you to weld most coated electrodes from Ø 1.6 to Ø 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.

ately 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 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

pletely.

If you are working on a welding bench, check before attempting to strike the arc that residual waste metal, pieces of electrode or other objects on the bench 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.

cmha2p11

When you want to weld wide beads, or when you want the weld

ever, you have to use lateral movements.

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5.6 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 where high quality is demanded and for welding thin plate. Arc 151i also has good characteristics for TIG welding.

In order to TIG weld the power source must be equipped with:

a TIG torch with gas valve a welding gas cylinder (a suitable welding gas) a welding gas regulator (suitable gas regulator) tungsten electrode suitable auxiliary material, if necessary.

”Live TIG-start” (only A33 control panel)

With “Live TIG start” the arc strikes when the tungsten electrode is brought into contact with the workpiece and then lifted away from it.

5.7 Remote control unit

The remote control unit is connected to the remote control socket on the power source.

6 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Only those persons who have appropriate electrical knowledge (authorized personnel) may remove the safety plates to connect or carry out service, maintenance or repair work on welding equipment.

CAUTION

All guarantee undertakings from the supplier cease to apply if the customer attempts any work to rectify any faults in the product during the guarantee period.

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6.1 Inspection and cleaning

Power source

Check regularly that the welding power source is not clogged with dirt.

How often and which cleaning methods apply depend on: the welding process, arc times, placement, and the surrounding environment. It is normally sufficient to blow down the power source with dry compressed air (reduced pressure) once a year.

Clogged or blocked air inlets and outlets otherwise result in overheating.

TIG torch

The TIG torch's wear parts should be cleaned and replaced at regular intervals in order to achieve trouble-free welding.

7 FAULT-TRACING

Try these recommended checks and inspections before sending for an authorized service technician.

Type of fault Corrective action

No arc. Check that the mains power supply switch is turned on.

Check that the welding current supply and return cables are correctly connected.

Check that the correct current value is set. Check to see whether the MCB has tripped.

Check whether the thermal cut-outs have tripped (indicated

ted during welding.

quently.

Poor welding performance. Check that the welding current supply and return cables are

by the orange lamp on the front panel). Check the mains power supply fuses.

Check to see whether the dust filter is clogged. Make sure that you are not exceeding the rated data for the

power source (i.e. that the unit is not being overloaded).

correctly connected. Check that the correct current value is set. Check that the correct electrodes are being used. Check the gas flow.

7.1 Fault codes

Arc 151i comes with built-in fault monitoring. If a fault occurs, a code is shown in the

display. See instruction manual for the control panel.

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8 ORDERING SPARE PARTS

Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts.

Arc 151i is designed and tested in accordance with the international and European standards 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.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of this publication.

9 DISMANTLING AND SCRAPPING

Welding equipment primarily consists of steel, plastic and non-ferrous metals, and must be handled according to local environmental regulations. Coolant must also be handled according to local environmental regulations.

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 accordance 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.

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Diagram

Arc 151i

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Arc 151i

Order number

Ordering no. Denomination Type

0460 445 873 Welding Power source Caddy Arc 151i, A33

Australian version

0460 449 074 Instruction manual Control panel Caddy A32, A33, A33

0459 839 028 Spare parts list Caddy Arc 151i, A33

Instruction manuals and the spare parts list are available on the Internet at www.esab.com

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Arc 151i

Accessories

Strap. . .... .... ... ... ... ....... ... .... . .0460 265 001

Cable holder 2 pc. ... ... ... ... ....... .... 0460 265 002

Shoulder strap. . ... ... ... ... ... ... ...... .0460 265 003

Trolley. ... . .

for 5-10 litre gasbottle. . ... .... ... .... ... .0459 366 885

Welding cable kit, Arc 151i. . .......... . . . . .0700 006 898

Return cable kit, Arc 151i. . ... .... ..... ... . .0700 006 899

Tig torch TXH 150V, Arc 151i . . ... ......... .0700 300 538

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Arc 151i

Remote control MMA 1 (10 m cable). . ... ......

0349 501 024

MMA and TIG: current

Foot control FS002. . ... .... . . . . ... ... .......0349 090 886

MMA and TIG current

Remote control unit AT1 . . ... .... . . . . ........0459 491 896

MMA and TIG: current

Remote control unit AT1 CF. . ... ... ... ........0459 491 897

MMA and TIG: rough and fine setting of current.

Remote cable 12 pole - 8 pole

5 m . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . .0459 552 880

10 m . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . .0459 552 881

15 m . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . .0459 552 882

25 m . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . .0459 552 883

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NOTES

.............................................................................................................................................................

notes

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ESAB subsidiaries and representative oces

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

BULGARIA

ESAB Kft Representative Office Sofia Tel/Fax: +359 2 974 42 88

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03

FINLAND

ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71

FRANCE

ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24

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: +36 1 20 44 182 Fax: +36 1 20 44 186

ITALY

ESAB Saldatura S.p.A. Bareggio (Mi) Tel: +39 02 97 96 8.1 Fax: +39 02 97 96 87 01

THE NETHERLANDS

ESAB Nederland B.V. Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44

NORWAY

AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03

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

ROMANIA

ESAB Romania Trading SRL Bucharest Tel: +40 316 900 600 Fax: +40 316 900 601

RUSSIA

LLC ESAB Moscow Tel: +7 (495) 663 20 08 Fax: +7 (495) 663 20 09

SLOVAKIA

ESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41

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: +46 31 50 95 00 Fax: +46 31 50 92 22

ESAB international AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60

SWITZERLAND

ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55

UKRAINE

ESAB Ukraine LLC Kiev Tel: +38 (044) 501 23 24 Fax: +38 (044) 575 21 88

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/Pacic

AUSTRALIA

ESAB South Pacific Archerfield BC QLD 4108 Tel: +61 1300 372 228 Fax: +61 7 3711 2328

CHINA

Shanghai ESAB A/P Shanghai Tel: +86 21 2326 3000 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 45 670 7073 Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd USJ Tel: +603 8023 7835 Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Pacific Pte Ltd Singapore Tel: +65 6861 43 22 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

Africa

EGYPT

ESAB Egypt Dokki-Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13

SOUTH AFRICA

ESAB Africa Welding & Cutting Ltd Durbanvill 7570 - Cape Town Tel: +27 (0)21 975 8924

Distributors

For addresses and phone numbers to our distributors in other countries, please visit our home page

www.esab.com

ESAB Arc 151i A33 Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual