ESAB CaddyArc 150 Instruction Manual

GB

Valid for serial no. 316--xxx--xxxx, 328--xxx--xxxx,
341--xxx--xxxx

0459 263 001 GB 041101

CaddyArc 150

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 DIRECTIVE 3........................................................

2SAFETY 3...........................................................

3 INTRODUCTION 4...................................................

3.1 Equipment 4................................................................

4 TECHNICAL DATA 5.................................................

5 INSTALLATION 5....................................................

5.1 Placing 5...................................................................

5.2 Rating plate 5...............................................................

5.3 Mains power supply 6........................................................

6 OPERATION 6.......................................................

6.1 Connections and control devices 6............................................

6.2 Control panel 7.............................................................

6.3 Settings 8..................................................................

6.4 Overheating protection 8.....................................................

6.5 MMA welding 8.............................................................

6.6 TIG welding 9...............................................................

6.7 Remote control unit 9........................................................

7 MAINTENANCE 10....................................................

7.1 Cleaning the dust filter 10.....................................................

8 FAULT TRACING 10...................................................

8.1 Fault codes 11...............................................................

9 ORDERING SPARE PARTS 11..........................................

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

ORDERING NUMBER 14.................................................

SPARE PARTS LIST 15...................................................

ACCESSORIES 16.......................................................

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1DIRECTIVE

DECLARATION OF CONFORMITY

ESAB Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guarantee that welding
power source CaddyArc 150 from serial number 316 complies with standard IEC/EN 60974--1, in ac­cordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with stan­dard EN 50199 in accordance with the requirements of directive (89/336/EEC) and addendum
(93/68/EEC).

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Henry Selenius
Vice President
ESAB AB Arc Equipment
SE--695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924

Laxå 2003--04--10

2SAFETY

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 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 welding
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 welding equipment must be familiar with:

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

2. The operator must ensure that:

S no unauthorized 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.

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WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU­TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can kill

S Install and earth the welding 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.

PROTECT YOURSELF AND OTHERS!

ESAB can provide you with all necessary welding protection an d accessories.

WARNING!

Read and understand the instruction manual before installing
or operating.

Do not use the power source for thawing frozen pipes.

WARNING!

This product is solely intended for arc welding.

3 INTRODUCTION

The CaddyArc 150 is a welding current power source intended for use with coated
electrodes (MMA welding) and TIG welding.

3.1 Equipment

The CaddyArc 150 is supplied with 3 m of mains cable and an instruction manual.
ESAB’s accessories for the product can be found on page 16.

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4 TECHNICAL DATA

CaddyArc 150

Mains voltage 230 V, 1 µ 50/60 Hz
Fuse (delayed--action) 16 A
Primary current I

max

36 A

Primary current I

eff

21 A

Voltage/current range (DC) 4 A /20 V -- 150 A /26 V
Maximum permissible load at

25% duty cycle
35% duty cycle
60% duty cycle

100% duty cycle

150 A / 26 V
140 A / 26 V
110A/25V

90 A / 24 V

Power factor at maximum current 0,62
Efficiency at maximum current 77%
Open--circuit voltage 71--78 V
Operating temperature -- 1 0 ˚C-- +40˚ C
Constant A--weighed sound pressure <70db
Dimensions, l x b x h 394 x 267 x 274 mm
Weight 9kg
Enclosure class IP 23C
Application class

Duty cycle

The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer­tain load without overloading.

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.

5 INSTALLATION

The installation must be executed by a professional.

WARNING!

This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the user’s responsibility to take adequate precautions.

5.1 Placing

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

5.2 Rating plate

The rating plate is located on the underside of the power source.

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5.3 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. The standards for the country in
question must be complied with as regards the m ains cable area. A protective earth
connection must be made in accordance with regulations.

5.3.1 Recommended fuse sizes and minimum cable areas

CaddyArc 150

Mains voltage 230 V ¦10 %, 1--phase
Mains frequency 50--60 Hz
Fuse (delayed--action)

100A 20% duty cycle
120A 35% duty cycle
150A 35% duty cycle

10 A
16 A

20 A*)

Mains cable, area 3x2.5mm

2

Welding cable, area 16 mm

2

*) Note! The installed plug is approved for max. 16A.

North American version: The mains cable is approved for maximun 18 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.

6OPERATION

6.1 Connections and control devices

1 Main power supply switch, 0 / 1 4 Connection for remote control
2 Mains cable 5 Welding cable connector (+)
3 Connection for return cable (--) 6 Control panel (see 6.2)

3 and 5 are used for welding current supply and return cable connection during MMA

welding

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