GB
Caddy™
Arc 151i, Arc 201i
Instruction manual
Valid for serial no. 803-xxx-xxxx0460 446 001 GB 091020
1 DIRECTIVE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Equipment 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Control panel 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Location 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Mains power supply 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Recommended fuse sizes and minimum cable area 7. . . . . . . . . . . . . . . . . . . . . . .
6 OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 PFC - Power factor correction 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Connections and control devices 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Connection of welding and return cable 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Overheating protection 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 MMA welding 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 TIG welding 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 Remote control unit 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 MAINTENANCE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Inspection and cleaning 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 FAULT-TRACING 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Fault codes 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 ORDERING SPARE PARTS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 DISMANTLING AND SCRAPPING 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rights reserved to alter specifications without notice.
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1 DIRECTIVE
ESAB AB, Welding Equipment, SE-695 81 Laxå, Sweden, gives its unreserved guarantee that weld
DECLARATION OF CONFORMITY
ing power source Arc 151i, Arc 201i from serial number 803 are constructed and tested in compliance
with the standard EN 60974-1 and EN 60974-10 (Class A) in accordance with the requirements of
directive (2006/95/EC) and (2004/108/EEC).
--------------------------------------------------------------------------------------------------------------
Laxå 2008-01-25
Kent Eimbrodt
Global Director
Equipment and Automation
2 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
equipment. The following recommendations should be observed in addition to the standard regulations that apply to the work
place.
All work must be carried out by trained personnel well-acquainted with the operation of the welding equipment. Incorrect oper
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:
its operation
location of emergency stops
its function
relevant safety precautions
welding
2. The operator must ensure that:
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
3. The workplace must:
be suitable for the purpose
be free from drafts
4. Personal safety equipment
Always wear recommended personal safety equipment, such as safety glasses, flame-proof clothing, safety gloves.
Note! Do not use safety gloves when replacing wire.
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 extinquishing equipment must be clearly marked and close at hand.
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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 precausions when welding.
Ask for your employer's safety practices which should be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
Install and earth the welding 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 difficulties 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.
3 INTRODUCTION
Arc 151i, Arc 201iis 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 19.
3.1 Equipment
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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.
3.2 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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4 TECHNICAL DATA
Arc 151i Arc 201i
Mains voltage 230 V, 1 50/60 Hz 230 V, 1 50/60 Hz
Primary current
TIG
I
max
I
MMA
max
Mains supply Z
No-load power 30 W 30 W
Voltage/current range, MMA
A31
A33 4 A /20 V - 150 A /26 V 4 A /20 V - 170 A /26.8 V
Voltage/current range TIG 3 - 150 A 3 - 220 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 0.99 0.99
Efficiency at maximum current 80% 81%
Open-circuit voltage
A31
A33
Operating temperature -10° C - +40° C -10° C - +40° C
Transportation temperature -20° C - +55° C -20° C - +55° C
Constant A-weighted sound pressure < 70 dB < 70 dB
Dimensions, l x b x h 418 x 188 x 208 mm 418 x 188 x 208 mm
Weight
with A31
with A33
Enclosure class IP 23 IP 23
Application class
13.8 A
21.3 A
0.35 ohm Z
max
8 A /20 V - 150 A /26 V -
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
58 - 72 V
72 V
7.9 kg
8.1 kg
24.1 A
24.9 A
0.30 ohm
max
170 A / 26.8 V
130 A / 25.2 V
110 A / 24.4 V
220 A / 18.8 V
150 A / 16.0 V
110 A / 14.4 V
72 V
-
8.3 kg
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 at a cer
tain 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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5 INSTALLATION
The installation must be executed 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
distrubution network operator if necessary, that the equipment may be connected.
5.1 Location
Position the power source such that its cooling air inlets and outlets are not
obstructed.
5.2 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
5.2.1 Recommended fuse sizes and minimum cable area
Arc 151i Arc 201i
Mains voltage 230 V 10 %, 1-phase 230 V 10 %, 1-phase
Mains frequency 50-60 Hz 50-60 Hz
Mains cable, area 3G2.5 mm
Phase current I
Welding cable, area 16 mm
Fuse
anti-surge
type C MCB
1eff
11.5 A 13.4 A
2
16 A
13 A
2
3G2.5 mm
16 mm
16 A
16 A
2
2
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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6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
6.1 PFC - Power factor correction
The Caddy Arc 151i/201i are 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. Caddy Arc 151i/201i can operate with extra long
mains cables, over 100 m, giving you a very larger working radius.
6.2 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, see under 3.2 6 Mains cable
4 Connection (+)
MMA: for return cable or welding cable
TIG: for Tig torch l
6.3 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
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