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Esab
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Arc 201i
Instruction Manual
26 pgs2.75 Mb0
Table of contents
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Esab Arc 151i, Arc 201i Instruction Manual

Caddy®
Arc 151i, Arc 201i
Instruction manual
0460 446 301 GB 20190619
Valid for: serial no. 840-xxx-xxxx

TABLE OF CONTENTS

1
2
3
4
INSTALLATION............................................................................................ 10
4.1 Location................................................................................................... 10
4.2 Mains power supply ............................................................................... 10
4.2.1 Recommended fuse sizes and minimum cable area............................ 10
5
OPERATION ................................................................................................ 11
5.1 PFC - Power factor correction............................................................... 11
5.2 Connections and control devices ......................................................... 11
5.3 Connection of welding and return cable .............................................. 12
5.4 Overheating protection .......................................................................... 12
5.5 MMA welding........................................................................................... 12
5.6 TIG welding ............................................................................................. 13
5.7 Remote control unit................................................................................ 14
6
MAINTENANCE........................................................................................... 15
6.1 Inspection and cleaning......................................................................... 15
7
TROUBLESHOOTING ................................................................................. 16
7.1 Fault codes.............................................................................................. 16
8
ORDERING SPARE PARTS........................................................................ 17
DIAGRAM ............................................................................................................ 18
ORDERING NUMBERS ....................................................................................... 22
ACCESSORIES ................................................................................................... 23
Rights reserved to alter specifications without notice.
0460 446 301 © ESAB AB 2019

1 SAFETY

1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!
DANGER! Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING! Means potential hazards which could result in personal injury or loss of life.
CAUTION! Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual and follow all labels, employer´s safety practices and Safety Data Sheets (SDSs).

1.2 Safety precautions

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
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© ESAB AB 2019
1 SAFETY
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
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your body between the torch and work cables. Never coil the torch or work cable around your body. Keep welding power source and cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
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.
0460 446 301
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
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© ESAB AB 2019
1 SAFETY
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only qualified people remove covers for maintenance and troubleshooting as necessary. Reinstall panels or covers and close doors when service is finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable materials nearby.
• Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
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.
NOTE! Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/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.
ESAB has an assortment of welding accessories and personal protection equipment for purchase. For ordering information contact your local ESAB dealer or visit us on our website.
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© ESAB AB 2019

2 INTRODUCTION

2 INTRODUCTION
Arc 151i, Arc 201i is a welding current power source intended for use with coated electrodes (MMA welding) and TIG welding.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual.

2.1 Equipment

Arc 151i, Arc 201i is supplied with a 3 m welding cable, return cable, 3 m mains cable and an instruction manual for power source and control panel.
Instruction manuals in other languages can be downloaded from the website, www.esab.com.

2.2 Control panel

Control panel A31
• Knob for setting the current
• Mains voltage LED (green)
• Thermal overload trip indicator (yellow)
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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© ESAB AB 2019

3 TECHNICAL DATA

3 TECHNICAL DATA
Arc 151i Arc 201i
Mains voltage 230 V, 1 ~ 50/60 Hz 230 V, 1 ~ 50/60 Hz
Primary current:
I
TIG 13.8 A 24.1 A
max
I
MMA 21.3 A 24.9 A
max
No-load power 30 W 32 W
Voltage/current range, MMA:
A31 8 A / 20 V - 150 A / 26 V -
A33 4 A / 20 V - 150 A / 26 V 4 A / 20 V - 170 A / 26.8 V
Voltage/current range TIG 3A / 10V - 150 A / 16V 3A / 10V - 220A / 18V
Permissible load at MMA:
25% duty cycle 150 A / 26.0 V 170 A / 26.8 V
60% duty cycle 100 A / 24.0 V 130 A / 25.2 V
100% duty cycle 90 A / 23.6 V 110 A / 24.4 V
Permissible load at TIG:
20% duty cycle - 220 A / 18.8 V
25% duty cycle 150 A / 16.0 V -
60% duty cycle 120 A / 14.8 V 150 A / 16.0 V
100% duty cycle 110 A / 14.4 V 110 A / 14.4 V
Power factor at maximum current 0.99 0.99
Efficiency at maximum current 80% 81%
Open-circuit voltage:
A31 without VRD function
1)
A33 VRD function deactivated
VRD function activated
2)
2)
58 - 72 V -
56 V 56 V
23 V 22 V
Operating temperature -10 °C - +40 °C -10 °C - +40 °C
Transportation temperature -20 °C - +55 °C -20 °C - +55 °C
Constant A-weighted sound
< 70 dB < 70 dB
pressure
Dimensions (l × b × h) 418 × 188 × 208 mm 418 × 188 × 208 mm
Weight:
with A31 7.9 kg -
with A33 8.1 kg 8.3 kg
Enclosure class IP 23 IP 23
Application class
1) Valid for power sources without VRD specification on the rating plate.
2) Valid for power sources with VRD specification on the rating plate. The VRD function is explained in the instruction manual for the control panel.
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© ESAB AB 2019
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