ESAB Arc 251i - Caddy Arc 251i Instruction manual

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Caddy®

Arc 251i

Instruction manual

0460 324 101 GB 20210831

Valid for: from serial no. 112-xxx-xxxx

SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

INTRODUCTION

2.1 Equipment

2.2 Control panel A32, A34

TECHNICAL DATA

INSTALLATION

4.1 Location

4.2 Mains supply

4.3 Mains power supply

4.3.1 Recommended fuse sizes and minimum cable area............................ 10

OPERATION

5.1 Connections and control devices

5.2 Connection of welding and return cable

5.3 TIG welding

5.4 Overheating protection

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MAINTENANCE

6.1 Power source

6.2 Welding torch

TROUBLESHOOTING

ORDERING SPARE PARTS

DIAGRAM

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ORDERING NUMBERS ACCESSORIES

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15 16 18 19

Rights reserved to alter specifications without notice.

0460 324 101 © ESAB AB 2021

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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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.

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NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

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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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2 INTRODUCTION

Arc 251i 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

The power source is supplied with:

• Instruction manual for the welding power source

• Instruction manual for the control panel

• 3 m return cable

• 3 m welding cable

Instruction manuals in other languages can be downloaded from the Internet: www.esab.com

2.2 Control panel A32, A34

Welding process parameters are controlled via the control panel.

See the separate instruction manual for a detailed description of the control panels.

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3 TECHNICAL DATA

Arc 251i

Mains voltage 400V ±15%, 3~ 50/60Hz

Mains supply S

sc min

3.3MVA

Primary current

MMA 14A

max

TIG 10A

max

No-load power demand when in the

30W

energy-saving mode, 6.5 min. after welding

Setting range

MMA 4–250A

TIG 3–250A

Permissible load at MMA

30% duty cycle 250A / 30V

60% duty cycle 190A / 27.6V

100% duty cycle 150A / 26V

Permissible load at TIG

30% duty cycle 250A / 20V

60% duty cycle 190A / 17.6V

100% duty cycle 150A / 16V

Power factor at maximum current

MMA 0.94

TIG 0.93

Efficiency at maximum current

MMA 83%

TIG 79%

Open-circuit voltage

without VRD 65V

with VRD <35V

Operating temperature -10 to +40°C (+14 to +104°F)

Transportation temperature -20 to +55°C (-4 to +131°F)

Continual sound pressure at no-load <70db(A)

Dimensions lxwxh 418×188×208mm

(16.5×7.4×8.2in.)

Weight 10.5kg (23.1lb)

Insulation class transformer H

Enclosure class IP23

Application class

Mains supply, S

sc min

Minimum short circuit power on the network in accordance with IEC 61000-3-12.

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3 TECHNICAL DATA

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/104°F, or below.

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 intended 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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4 INSTALLATION

The installation must be carried out by a professional.

4.1 Location

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

4.2 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

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

. Refer to the technical data in the TECHNICAL DATA chapter.

scmin

at the interface point between the user's supply

scmin

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

Rating plate with supply connection data

4.3.1 Recommended fuse sizes and minimum cable area

Arc 251i

Mains voltage 400 V

Mains cable area (mm2)

4 G 1.5

Phase current (I

Fuse

anti-surge 10 A

type C MCB 10 A

NOTE!

The mains cable areas and fuse sizes as shown above are in accordance with Swedish regulations. For other regions, supply cables must be suitable for the application and meet local and national regulations.

0460 324 101

) 8 A

1eff

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5 OPERATION

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!

5.1 Connections and control devices

1 Mains voltage switch 4 Connection for remote control unit

2 Connection (+)

TIG: return cable

MMA: welding cable or return cable

3 Connection (-)

TIG: torch

MMA: return cable or welding cable

5 Control panel,

see separate instruction manual

5.2 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 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.

5.3 TIG welding

At TIG-welding complete the power source with:

• a TIG torch with gas valve

• an argon gas tube

• an argon gas regulator

• tungsten electrode

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5 OPERATION

5.4 Overheating protection

The welding power source has overheating protection that operates if the temperature becomes too high. When this occurs the welding current is interrupted and a fault code is displayed on the control panel.

The overheating protection resets automatically when the temperature has fallen.

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6 MAINTENANCE

NOTE!

Regular maintenance is important for safe and reliable operation.

CAUTION!

Only persons with the appropriate electrical knowledge (authorised personnel) may remove the safety plates.

CAUTION!

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

6.1 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

• positioning of welding power source

• the surrounding environment.

It is normally sufficient to blow the power source clean with dry compressed air (reduced pressure) once a year.

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

6.2 Welding torch

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

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7 TROUBLESHOOTING

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

Type of fault Corrective actions

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 the mains power supply fuses.

The welding current is interrupted during welding.

• Check whether the thermal overload protections have tripped (a fault code is displayed on the control panel).

• Check the mains power supply fuses.

The thermal overload protection trips frequently.

• Make sure that you are not exceeding the rated data for the welding power source (i.e. that the unit is not being overloaded).

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

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

are correctly connected.

• Check that the correct current value is set.

• Check that the correct electrodes are being used.

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8 ORDERING SPARE PARTS

Arc 251i 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 mentioned standard.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see

esab.com. When ordering, please state product type, serial number, designation and spare

part number in accordance with the spare parts list. This facilitates dispatch and ensures correct delivery.

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DIAGRAM

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DIAGRAM

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ORDERING NUMBERS

Ordering no. Denomination Type

0460 300 880 Welding power source Caddy® Arc 251i, A32

0460 300 881 Welding power source Caddy® Arc 251i, A34

0459 839 021 Spare parts list Arc 251i

0460 449 * Instruction manual Control panel Caddy® A32, A34

The three last digits in the document number of the manual show the version of the manual. Therefore they are replaced with * here. Make sure to use a manual with a serial number or software version that corresponds with the product, see the front page of the manual.

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

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ACCESSORIES

0459 491 896 Remote control unit AT1

MMA and TIG: setting of current

0459 491 897 Remote control unit AT1 CF

MMA and TIG: rough and fine setting of current

0349 090 886 Foot pedal FS002 with 5 m cable

 0459 552 880

0459 552 881

0459 552 882

0459 552 883

0700 006 902 0700 006 903

Remote cable 12 pole - 8 pole 5 m

10 m

15 m

25 m

Welding cable kit Return cable kit

0460 265 002 Cable holder

0460 265 003 Shoulder strap

0700 300 539 0700 300 545

0700 300 553

0700 300 556

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Tig torch TXH 151V 4 m Tig torch TXH 151V 8 m

Tig torch TXH 201V 4 m

Tig torch TXH 201V 8 m

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ACCESSORIES

 0459 366 885

 0459 366 886

 0460 330 880

Trolley for 5-10 litre gascylinder

Trolley for 20-50 litre gascylinder

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ACCESSORIES

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ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00

http://manuals.esab.com

For contact information visit esab.com

ESAB Arc 251i - Caddy Arc 251i Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

1 SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

2 INTRODUCTION

2.1 Equipment

2.2 Control panel A32, A34

3 TECHNICAL DATA

4 INSTALLATION

4.1 Location

4.2 Mains supply

4.3 Mains power supply

4.3.1 Recommended fuse sizes and minimum cable area

5 OPERATION

5.1 Connections and control devices

5.2 Connection of welding and return cable

5.3 TIG welding

5.4 Overheating protection

6 MAINTENANCE

6.1 Power source

6.2 Welding torch

7 TROUBLESHOOTING

8 ORDERING SPARE PARTS

DIAGRAM

ORDERING NUMBERS

ACCESSORIES