ESAB Caddy 250 Arc 251i Instruction manual

GB

Caddy

Arc 251i

Instruction manual

Valid for serial no. 810-xxx-xxxx0460 324 001 GB 20120731

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1 SAFETY 4...........................................................

2 INTRODUCTION 6...................................................

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

2.2 Control panel A32, A34 6.....................................................

3 TECHNICAL DATA 7.................................................

4 INSTALLATION 8....................................................

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

4.2 Mains supply 8..............................................................

4.3 Mains power supply 8........................................................

4.3.1 Recommended fuse sizes and minimum cable area 8.......................

5 OPERATION 9.......................................................

5.1 Connections and control devices 9............................................

5.2 Connection of welding and return cable 9.......................................

5.3 TIG welding 10...............................................................

5.4 Overheating protection 10.....................................................

6 MAINTENANCE 10....................................................

6.1 Power source 10.............................................................

6.2 Welding torch 10.............................................................

7 FAULT-TRACING 11..................................................

8 ORDERING SPARE PARTS 11.........................................

DIAGRAM 12............................................................

ORDER NUMBER 14.....................................................

ACCESSORIES 15.......................................................

Rights reserved to alter specifications without notice.

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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 ob served 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 equip ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in jury to the operator and damage to the equipment.

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

S its operation S location of emergency stops S its function S relevant safety precautions S welding and cutting

2. The operator must ensure that: S no unauthorised 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. S Lubrication and maintenance must not be carried out on the equipment during operation.

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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

S Install and earth the 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 your 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 your ears. Use earmuffs or other hearing protection. S 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

This product is solely intended for arc welding.

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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.

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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.

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

2 INTRODUCTION

Arc 25li 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 95.

2.1 Equipment

The power source is supplied with:

S Instruction manual for the welding power source

S Instruction manual for the control panel

S 3 m return cable

S 3 m welding cable

Instruction manuals in other languages can be downloaded from the website, 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 Primary current

MMA

I

max

I

TIG

max

No-load power demand when in the energy-saving mode, 6.5 min. after welding 30 W

Setting range

MMA TIG

Permissible load at MMA 30 % duty cycle 60 % duty cycle 100% duty cycle

Permissible load at TIG 30 % duty cycle 60 % duty cycle 100% duty cycle

Power factor at maximum current MMA TIG

Efficiency at maximum current MMA TIG

Open-circuit voltage

without VRD with VRD

Operating temperature -10 to +40° C Transportation temperature -20 to +55° C Continual sound pressure at no-load <70 db (A) Dimensions lxwxh 418 x 188 x 208 mm Weight 10.5 kg Insulation class transformer H Enclosure class IP 23 Application class

3.3 MVA

sc min

14 A 10 A

4 - 250 A 3 - 250 A

250 A / 30 V 190 A / 27.6 V 150 A / 26 V

250 A / 20 V 190 A / 17.6 V 150 A / 16 V

0.94

0.93

83 % 79 %

65 V < 35 V

Mains supply, S

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

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.

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4 INSTALLATION

The installation must be carried out by a professional.

4.1 Location

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

4.2 Mains supply

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.

4.3 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 400V

1eff

2

4 G 1.5

8 A

10 A 10 A

Mains cable area mm

Phase current I

Fuse

anti-surge type C MCB

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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5 OPERATION

General safety regulations for handling the equipment can be found on page 84. Read 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.

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5.3 TIG welding

At TIG-welding complete the power source with:

S a TIG torch with gas valve

S an argon gas tube

S an argon gas regulator

S tungsten electrode

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.

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.

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.

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:

S the welding process

S arc times

S placement

S 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 FAULT-TRACING

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

Type of fault Corrective 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 the mains power supply fuses.

The welding current is interrupted during welding.

The thermal cut-out trips frequently.

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

S Check whether the thermal cut-outs have tripped (a fault

code is displayed on the control panel).

S Check the mains power supply fuses.

S Make sure that you are not exceeding the rated data for the

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

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

correctly connected.

S Check that the correct current value is set. S Check that the correct electrodes are being used.

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 said standard.

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

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Diagram

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Arc 251i

Order number

Ordering no. Denomination Type

0460 300 880 Welding power source Caddyâ Arc 251i, A32

0460 300 881 Welding power source Caddyâ Arc 251i, A34

0459 839 021 Spare parts list Arc 251i

0460 449 Instruction manual Control panel Caddyâ A32, A34

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

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Arc 251i

Accessories

Remote control unit AT1 .................

MMA and TIG: setting of current

Remote control unit AT1 CF .............

MMA and TIG: rough and fine setting of current

Foot pedal FS002 with 5 m cable .......... 0349 090 886

Remote cable 12 pole - 8 pole

5 m.....................................

10 m....................................

15 m....................................

25 m....................................

0459 491 896

0459 491 897

0459 552 880 0459 552 881 0459 552 882 0459 552 883

Welding cable kit ........................

Return cable kit .........................

Cable holder ............................ 0460 265 002

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

0700 006 902

0700 006 903

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Arc 251i

Tig torch TXH 150 4 m ..................

Tig torch TXH 150 8 m ...................

Tig torch TXH 200 4 m ..................

Tig torch TXH 200 8 m ..................

0460 011 843 0460 011 883 0460 012 841 0460 012 881

Trolley ......

for 5-10 litre gascylinder ...................

0459 366 885

Trolley

for 20-50 litre gascylinder .................. 0459 366 886

Trolley

for 20-50 litre gascylinder ................. 0460 330 880

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NOTES

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notes

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NOTES

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notes

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NOTES

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notes

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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

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/Pacific

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 Caddy 250 Arc 251i Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual