Page 1
HELIARC AC/DC
HELIARC AC/DC
281i, 283i & 353i
281i, 283i & 353i
Operating Manual
0558 012079 10/2014
Page 2
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
2
PROTECT YOURSELF AND OTHERS!
Page 3
TABLE OF CONTENTS
SECTION TITLE .................................................................................................................................PAGE
SECTION 1 SAFETY ....................................................................................................................................................................... 4
SECTION 2 INTRODUCTION ...................................................................................................................................................... 9
SECTION 3 INSTALLATION ....................................................................................................................................................... 11
SECTION 4 ASSEMBLY ............................................................................................................................................................... 13
SECTION 5 OPERATION ............................................................................................................................................................19
SECTION 6 MAINTENANCE......................................................................................................................................................45
SECTION 7 WARRANTY ............................................................................................................................................................. 47
3
Page 4
SECTION 1 SAFETY
Safety - Introduction
ESAB welding equipment is designed to operate both safely and eectively. Sensible attention to operating
procedures, precautions, and safe practices is required to achieve a full measure of usefulness. Whether an
individual is involved with operation, servicing, or as an observer, compliance with established precautions
is mandatory. Failure to observe precautions could result in equipment damage, serious injury, or death.
The following precautions are guidelines when working with cutting machines and associated equipment.
More explicit precautions are found within the instruction literature. For specic safety and industry-related
information, obtain and read publications listed in Recommended References.
The following words and symbols are used throughout this manual to indicate dierent levels of required
safety involvement:
USED TO CALL ATTENTION TO HIGH RISK HAZ
ARDS, WHICH IF NOT AVOIDED, WILL RESU LT
DANGER
IN DEATH OR SERIOUS INJURY.
WARNING
CAUTION
USED TO CALL ATTENTION TO MEDIUM RISK
HAZARDS, WHICH IF NOT AVOIDED, COULD RE
SULT IN DEATH OR SERIOUS INJURY.
USED TO CALL ATTENTION TO LOW RISK HAZ
ARDS, WHICH IF NOT AVOIDED, COULD RESULT
IN MINOR OR MODERATE INJURY.
USED TO CALL ATTENTION TO IMPORTANT IN
FORMATION NOT DIRECTLY RELATED TO SAFE
TY HAZARDS OR COULD POTENTIALLY CAUSE
EQUIPMENT DAMAGE.
4
Page 5
SECTION 1 SAFETY
Safety
WARNING: These Safety Precautions are
for your protection. They summarize
precautionary information from the
references listed in Additional Safety
Information section. Before per forming
any installation or operating procedures, be sure
to read and follow the safety precautions listed
below as well as all other manuals, material safety
data sheets, labels, etc. Failure to observe Safety
Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, e mits
ultraviolet (UV) and other radiation and can injure
skin and eyes. Hot metal can cause burns. Training
in the proper use of the processes and equipment
is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield tted with the correct lter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operating
or observing operations. Warn bystanders not to
watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.
3. Wear ameproof gauntlet type gloves, heavy long-
sleeve shirt, cuess trousers, high-topped shoes,
and a welding helmet or cap for hair protection, to
protect against arc rays and hot sparks or hot metal.
A ameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cus, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing.
5. Protect other personnel from arc rays and hot sparks
with a suitable non-ammable partition or curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can y far.
Bystanders should also wear goggles over safety
glasses.
FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective
non-ammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in oors or wall openings and cause a hidden smoldering re or res on the oor below. Make
certain that such openings are protected from hot
sparks and metal.“
3. Do not weld, cut or perform other hot work until the
work piece has been completely cleaned so that there
are no substances on the work piece which might
produce ammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have re e xtinguishing equipment handy f or instant
use, such as a garden hose, water pail, sand bucket,
or portable re extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and
create a re hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later re. Use re watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protec tion
Association, Battery march Park, Quincy, MA 02269.
5
Page 6
SECTION 1 SAFETY
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is conned, or if there is
danger of falling.
1. Be sure the Plasma Console frame (chassis) is connected to the ground system of the input power.
2. Connect the work piece to a good electrical ground.
3. Connect the work cable to the work piece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and Plasma
Console.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
9. Turn o the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommendations. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current owing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding and cutting current creates EMF around
welding cables and welding machines. Therefore:
1. Welders having pacemakers should
consult their physician before welding. EMF may interfere with some
pacemakers.
2. Exposure to EMF may have other health eects
which are unknown.
3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connect the work cable to the work piece as close
as possible to the area being welded.
E. Keep welding Plasma Console and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discomfort persists.
6
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specic ventilation recommendations.
Page 7
SECTION 1 SAFETY
5. WARNING: This product, when used for welding
or cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylinder,
valve, or relief device can injure or kill.
Therefore:
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and ttings in good
condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas
cylinder.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure
cylinders to work tables or xtures where they may
become part of an electrical circuit.
2. Before performing any maintenance work inside
a Plasma Console, disconnect the Plasma Console
from the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and Plasma Console in safe working order. Do
not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For more
information on safe practices for electric
arc welding and cutting equipment, ask
your supplier for a copy of "Precautions
and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and ames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jeerson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualied personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied to perform such work.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc
Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc
Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon
Arc Gouging and Cutting”.
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal
Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, “Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting
and Allied Processes.
7
Page 8
SECTION 1 SAFETY
MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your
safety is involved.
DANGER
CAUTION
WARNING
Enclosure Class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or
water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and
against spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not intended to be used outside during precipitation unless sheltered.
CAUTION
CAUTION
If equipment is placed on a surface that slopes more
than 15°, toppling over may occur. Personal injury and
/ or signicant damage to equipment is possible.
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
Means potential hazards which could result in personal injury or loss of life.
Means hazards which could result in minor personal injury.
This product is solely intended for plasma cutting. Any other use may
result in personal injury and / or equipment damage.
CAUTION
CAUTION
CAUTION
To avoid personal injury and/or equipment damage, lift
using method and attachment points shown here.
8
maximum
allowable tilt
15°
Page 9
SECTION 2 INTRODUCTION
INTRODUCTION
The Heliarc AC/DC 281i, 283i and 353i are state of the art DC and squarewave AC power sources for SMAW
(MMA) or GTAW (TIG) welding. They utilize inverter based technology in combination with microprocessor control. The 281i and 283i models are rated 250A / 280A at 100% duty and the more powerful 353i model up to
350A@ 45% duty.
The operator control panel utilizes both rotary knobs together with membrane key-press switches to enable the
precise setting of the required welding parameters. Two easy to read digital displays provide a precise and clear
readout of the various welding data, both preset and actual.
For DC TIG welding applications the units feature both non-contact electronic arc ignition as well as non-HF lift
arc facilities. HF starting is employed for AC TIG but, unlike with other AC TIG systems, the HF is switched o
once the arc is established. This fact means that the possibility of electrical interference from the equipment is
greatly reduced.
The AC/DC 281i can be operated from a 1 Ph 208-240V supply protected with a 50A fuse or circuit breaker. The
AC/DC 283i and 353i require balanced 3Ph 460V industrial supply protected by a 16/32A fuse or circuit breaker
respectively, see specication below.
The power sources are constructed in rugged all metal enclosures incorporating convenient carrying handles.
Multiple fans at the rear provide cooling for the internal components. Full thermal overload protection is standard.
An auxiliary W.C.U. power receptacle is available on the rear panel when using a Heliarc Water Cooling Unit.
A trolley unit is another option available for these power sources. The Heliarc AC/DC 281i, 283i and 353i are designed, manufactured and tested to meet the requirements of EN60974-1 “Safety Requirements.
9
Page 10
SECTION 2 INTRODUCTION
Heliarc 281i/283i/353i AC/DC
For advanced GTAW (TIG) welding
Specifications
Heliarc 281i AC/DC
Input voltage 208-240 V 1 ph 50/60 H
Open circut voltage 75 75 75
Setting range, TIG AC/DC 4-280 A 4-280 A 4-350 A
Amps input at rated load, TIG 47 A 16.6 A 16.6 A
Amps input at 250 A, TIG 38 A 12.5 A 12.5 A
Maximum output, TIG AC/DC
100% duty cycle 250 A 280 A 280 A
60% duty cycle 270 A - 300 A
50% duty cycle 280 A - -
45% duty cycle - - 350 A
Power factor at maximum current, TIG 0.80 0.75 0.80
KVA max, TIG 10.5 11 14.5
0.1-2.5 0.1-2.5 0.1-2.5
0.1-30 0.1-30 0.1-30
Slope down, sec 0.1-10 0.1-10 0.1-10
Slope up, sec (for 283i and 353i) Not Applicable 0.1-10 0.1-10
Frequency AC 20-200 Hz 20-200 Hz 20-200 Hz
AC balance, % 10-90 10-90 10-90
DC pulse mode frequency 0.4-300 Hz 0.4-300 Hz 0.4-300 Hz
AC pulse mode frequency 0.4-2 Hz 0.4-2 Hz 0.4-2 Hz
Pulse duty (pulse time/background time) % 30-65 30-65 30-65
Background current % of main A 10-90 10-90 10-90
Start/crater current (4 stroke) % of main A 10-90 10-90 10-90
Setting range, Stick AC/DC 4-250 4-280 4-350
Maximum output, Stick AC/DC
100% duty cycle 200 A 220 A 220 A
60% duty cycle 220 A 240 A 240 A
40% duty cycle 250 A 280 A -
20% duty cycle - - 350 A
KVA max, Stick 12 14.2 19
Dimensions L x W x H 23.6 x 11.8 x 24.4 in.
(600 x 300 x 620 mm)
Weight 110 lb (50 kg) 110 lb (50 kg) 110 lb (50 kg)
Enclosure class IP 21S IP 21S IP 21S
460 V 3 ph 50/60 Hz
23.6 x 11.8 x 24.4 in.
(600 x 300 x 620 mm)
Heliarc 353i AC/DCHeliarc 283i AC/DC
460 V 3 ph 50/60 Hz
23.6 x 11.8 x 24.4 in.
(600 x 300 x 620 mm)
10
Page 11
SECTION 3 INSTALLATION
INSTALLATION
1. Radio Interference
ESAB welding power sources have been designed to high standards of electromagnetic compatibility. However,
arc welding, by its very nature, generates radio-frequency energy and may cause interference. By installing
and using the equipment correctly, in accordance with these instructions, the problems of interference may be
minimized.
This equipment satises the requirements of the EU Directive 89/336/EC on EMC and complies with the limits in
EN50199, ‘EMC product standard for arc welding equipment’. These limits are designed to provide reasonable
protection against interference in heavy industrial areas.
If this equipment is used in domestic areas, e.g. for repair or maintenance, particular care should be taken. The
time of day should be chosen and the duration of welding limited, to minimise any potential problems.
If this equipment causes interference the guidance given below should be considered. If a solution cannot be
found please contact your distributor or the manufacturer.
Before installing this welding equipment an assessment should be made of potential EMC problems that may
occur. It is good practice not to install welding equipment next to computers or safety critical control circuits,
e.g. electronic machine guards, unless they have been suitably protected.
This equipment should be connected to the primary supply using the cable provided. However, for permanent
installation, if interference problems occur, shielded cable or conduit should be considered. The primary cabling
and welding cables should be kept separate to other mains wiring and control, signalling or communications
leg (telephone) cables. If interference occurs then greater separation or re-routing should be considered.
Welding cables should be kept as short as practically possible.
Interference may also be reduced by separating the welding equipment from the other equipment aected.
A partition, brick wall or particularly, a metal screen will also reduce interference. Earthing and equi-potential
bonding should also be considered but guidance should be sought from a competent person, the distributor
or manufacturer.
To ensure continued compliance to the EMC Directive this equipment should be routinely maintained according
to the manufacturer’s instructions and using only approved spare parts. In particular, the spark gaps of HF
units should be adjusted and maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the equipment is being
used. This equipment should not be modied in any way except for those changes and adjustments approved
by the manufacturer.
2. Trolley Unit
Assemble the trolley/cylinder carrier unit if supplied. Refer to Figure 4.1 for assembly details. Locate the power
source on the sloping shelf; temporarily removing the gas cylinder support/chain holder bracket makes this
easier.
WARNING
DO NOT LET THE POWER SOURCE SLIDE BACKWARDS OFF THE SHELF
WHEN THE CYLINDER SUPPORT BRACKET IS NOT FITTED.
11
Page 12
SECTION 3 INSTALLATION
3. Connection to the Supply
The Heliarc AC/DC 281i requires a single phase 208-240V 60Hz electricity supply fused at 50A for all TIG welding
and Stick applications.
The 283i and 353i need a standard 3 phase 460V 60Hz electricity supply, note no neutral connection is required.
Supplies should be fused at 20A for the 283i and 32A for the 353i, using HRC type fuses.
If circuit breaker protection, rather than fuses, is to be used for any of the 3 machines, type D/4 breakers should
be used.
Ensure the green/yellow earth conductor is securely connected to a good mains earth.
4. Water Cooler Unit W.C.U. (0558101703)
If supplied install the W.C.U. in the base of the trolley by sliding it part way into the trolley base. Feed the W.C.U.
WARNING
primary cable through the hole/strain relief located on the rear of the W.C.U. compartment in the trolley. Slide
the W.C. unit completely into the housing. Locate the auxiliary W.C.U. receptacle on the upper left corner of the
rear panel. Plug the Water Cooler input plug into receptacle until it clicks. Secure with the W.C. unit with the
retaining bolt in the left side panel.
ENSURE POWER SOURCE IS ISOLATED FROM THE MAINS SUPPLY.
Green / Yellow
Figure 1 - 230VAC Auxiliary Connection
12
R S
230V
Page 13
SECTION 4 ASSEMBLY
SECTION 4
ASSEMBLY
TROLLEY ASSEMBLY fig. 4-1
13
Page 14
ASSEMBLY
SECTION 4 ASSEMBLY
TROLLEY ASSEMBLY fig. 4-2
14
Page 15
SECTION 4 ASSEMBLY
ASSEMBLY
POWER SOURCE TO TROLLEY ASSEMBLY fig. 4-3
15
Page 16
SECTION 4
ASSEMBLY
SECTION 4 ASSEMBLY
POWER SOURCE TO TROLLEY ASSEMBLY fig. 4-4
View From “A”
16
Page 17
SECTION 4 ASSEMBLY
ASSEMBLY
g
gy (
1_Turn off Cooler and Power Source and remove the cooler plug before filling up with liquid
COOLER ASSEMBLY fig. 4-5
3
4
5
6
7
8
2
1
ASSEMBLY SEQUENCE
1_Remove screws M5x12 (8) and door panel (7)
2_Insert the input cable with plu
plastic cap). Fasten the input cable with screws M5x12 (3) on the back panel (see view "A").
IMPORTANT OPERATION
1_Remove the plastic cap (5)
2_Once the Cooler is instal fasten the safety screw M6x16 (6)
COOLING LIQUID FILL UP
2_Remove the safety screw (6)
3_Pull out the Cooler and fill up with liquid.
4_Push back the Cooler and fasten the safety screw (6).
into the trolley. Take it out from the back hole (remove first the
.
17
Page 18
SECTION 4 ASSEMBLY
REMOVE UPPER EXTENSION PIECES * FOR 281i & 283i.
WARNING
Before energizing the cooler ensure it is correctly lled with coolant, refer to W.C.U. Instruction Sheet, and
connect the TIG torch cooling hoses to its front panel.
IMPORTANT
After running the cooler for a few minutes the coolant level should be checked and topped-up if necessary.
5. Connection of the TIG Torch, Work Return and Gas Hose
5.1 Connect the TIG torch power lead dins plug to the negative dins socket on the lower front of the power
source (marked with the torch symbol).
5.2 Water cooled TIG torches have the water return hose exiting from the side of the dins plug. This must be
connected to the red water return tting on the W.C.U. front panel. Connect the other water-in hose of the
torch to the blue water-out tting of the cooler.
ENSURE THE GREEN/YELLOW EARTH WIRE IS CORRECTLY CONNECTED TO
THE LH TERMINAL.
ENSURE THE W.C.U. IS CORRECTLY FILLED WITH COOLANT AND THAT
THE TIG TORCH WATER HOSES ARE CONNECTED BEFORE SWITCHING ON
THE POWER SOURCE. FAILURE TO DO SO MAY DAMAGE THE MOTOR AND
PUMP. USE PLASMA TORCH COOLANT.
NEVER USE AUTOMOTIVE ANTI-FREEZE TYPE COOLANTS. THEY WILL
CLOG THE TORCH AND CAUSE PREMATURE FAILURE.
5.3 Connect the TIG torch shielding gas hose to the ¼” BSP tting on the lower front panel.
5.4 Connect the TIG torch switch, if tted, to the 2 pin socket.
5.5 If required connect the remote control unit, eg. FC-5C foot control, to the 14 pin socket.
5.6 Connect the “B” 5/8”-18 gas-in tting on the rear panel to the shielding gas regulator/owmeter.
5.7 Connect the work return lead dins plug to the positive dins socket on the lower front panel.
6. Connections for Stick SMAW (MMA) Welding
6.1 Connect the SMAW electrode holder lead to the positive dins socket on the lower front of the power source.
Note that for DC SMAW applications this will make the electrode positive polarity.
6.2 Connect the work return lead dins plug to the negative dins socket.
IF A HELIARC W.C.U. TORCH WATER COOLER IS FITTED TO THE POWER
SOURCE WHEN SMAW WELDING, REMEMBER TO EITHER SWITCH OFF THE
WARNING
COOLER OR LEAVE THE TIG TORCH GO AND RETURN WATER HOSES CONNECTED TO IT. FAILURE TO DO THIS MAY DAMAGE THE COOLER.
18
Page 19
SECTION 5 OPERATION
OPERATION
CONTROLS & OPERATION
1. Switching On
1.1 The rear panel mounted rotary switch is the mains power ON/OFF switch.
THE COMPUTER CONTROL SYSTEM MEMORIZES THE POWER SOURCE
WARNING
Setting the power switch to “ON” energizes the internal circuitry including the rear panel cooling fans and
auxiliary W.C.U. supply for the optional torch water cooler. All the various LED indicators on the control
panel will momentarily illuminate. The left and right hand LED readouts will ash for a short period indicating
the process/mode selected i.e. depending on the machine settings at the previous mains switch-o.
CONTROL SETTINGS AT POWER OFF. IF THE UNIT WAS IN MMA MODE AT
SWITCH-OFF THEN WHEN THE UNIT IS SWITCHED ON, OCV WILL BE PRESENT AT THE WELDING OUTPUT.
1.2 After 3 seconds approx., the display will change to ‘STANDBY MODE’. See Figure 5 indicating the process/
mode selected according to the LED illuminated in the SELECT MODE window. The L.H. (“V”) digital display
will read 000 except in SMAW mode when it will show the open circuit voltage (70V approx.). The R.H. dis-
play shows the preset main welding current “A” as adjustable by the Main Setting Control. In addition the
mains power indicator will be on and, if the unit is in SMAW mode, the welding output indicator LED will also
be on showing that welding output voltage is present.
Other LEDs may also be illuminated depending on the machine’s previous usage.
1.3 After changing the process/mode selection or any other parameters, slope down time, AC frequency etc.,
the display will always revert to the standby mode within 3-5 seconds of the change being completed.
1.4 While welding the L.H. and R.H. digital displays show the actual values of the welding voltage V and welding
current A. Note the welding voltage measurement is at the power source output terminals and may be
slightly higher than the actual arc voltage due to cable drops etc.
2. Local/Remote Control Operation
2.1 Connect the remote control unit, e.g. FC-5C foot control, to the 14 pin remote control receptacle.
2.2 Set the required maximum welding current, corresponding with the maximum position of the remote control, using the Main Setting Control while the unit is in standby mode.
19
Page 20
SECTION 5 OPERATION
CONTROLS & OPERATION (con't.)
2.3 Momentarily press the Remote Control mode key. The REM. ON LED will light and the L.H. display will ash
"REM". Whilst the display is ashing set the minimum/start value of the remote control as required between
4A and 100A using the Main Setting Control and R.H. display.
NOTE:
If the remote minimum/start current value of the remote control is set higher than the main welding
current the arc will strike at the main welding current setting and no remote variation will be possible.
2.4 To quickly check or readjust the start current value momentarily press the Remote Control key.
2.5 To revert to local control mode, whilst the display is at standby, press and hold the Remote Control mode key
until the “REM ON” LED goes out.
3. TIG Arc Initiation
3.1 Pressing the HF ON key selects HF start mode and the associated LED illuminates for conrmation. Pressing
the key again selects Lift-arc mode (the LED o). For DC TIG welding either HF or Lift-arc strike modes can
be used, but HF should be used for AC TIG to prevent contamination of the tungsten.
3.2 Once the arc is established, in either AC or DC TIG, the HF is automatically turned o. HF is also disabled for
MMA operation.
4. AC or DC Process Selection
4.1 With the display in standby mode press the AC MODE key. The green ON AC light will illuminate and the digital displays will ash with the L.H. showing "Bal"(short for Balance) and the R.H. "Fre"(short for Frequency).
Whilst the displays ash, the AC Balance level can be preset using the lower "B" control knob between 10%
and 90% in the L.H. display. Also the AC Frequency can be adjusted from 20-200Hz as required using the
upper "F" control knob and the R.H. display.
Note the percentage balance refers to the negative "melting eect" of the arc so a lower balance % will
provide more cleaning action.
4.2 The AC Balance and AC Frequency settings can be adjusted whilst welding if required. To check the actual
values in use momentarily press the AC MODE key and the settings are shown in the L. H. and R.H. displays.
4.3 To revert to DC process, at standby press and hold the AC MODE key until the ON AC indicator LED turns o
(2-3 seconds).
20
Page 21
SECTION 5 OPERATION
SECTION 5 OPERATION
CONTROLS & OPERATION (con't.)
5. Selecting Pulse Mode - See Figure 7
Figure 7 - DC & AC Pulsing
5.1 In the standby mode, press the Pulse mode key (F). The associated green ON PULSE LED will illuminate and
the digital displays will ash "dut" L.H. and "Fre" in the R.H. Use the Main Setting Control to set the desired
pulse repeat frequency (0.4-300Hz DC; 0.4-2Hz AC) as indicated in the R.H. display.
5.2 Press the Pulse mode key (F) a 2nd time to set the pulse peak to background time ratio or "duty" shown in
the L.H. display using the Main Setting Control. Note this is settable in 5% increments in the range 30- 65%.
5.3 In the standby mode, press the Final Current/Background key (FC). Before the display stops ashing set
the required background current using the Main Setting Control. Note that background (or nal current)
is adjustable between 10% and 90% of the main (peak) current value. So for example, if the peak current
were set to 150A, and the background to 20%, during the background time the current would be 30A (20%
of 150A).
6. MMA Welding
6.1 Set the process/mode to Stick SMAW (MMA).
WARNING
6.2 Set the desired welding current using the welding current control A.
6.3 If required select AC process. See Subsection 4. Set the AC frequency (F) and balance (B) as desired, normally 60Hz and 50% Balance.
OPEN CIRCUIT VOLTAGE WILL NOW BE PRESENT AT THE WELDING
OUTPUT TERMINALS.
6.4 The machine is now ready to weld.
21
Page 22
SECTION 5 OPERATION
CONTROLS & OPERATION (con't.)
7. TIG Welding with 2 Stroke Torch Switch (2T) and HF Start - See Figure 8
Amps
Arc
Strike
A
Arc
O
Post
Purge
Time
Slope Up
Time
Torch
Switch
On O
Slope Down
Time t
2
Figure 8 - TIG 2T Operation
7.1 Set the process/mode to TIG 2T and press the HF ON key to select HF start.
7.2 Set the desired welding current with the main setting control A.
7.3 Set the required slope down time (0.1 - 10 secs) using the SL slope up/down
7.4 Set the required gas post purge time (0.2 - 30 secs) using the PG post gas key and main setting control.
7.5 If required choose AC process when the display is in standby mode. See Subsection 4.
7.6 If required choose pulse mode when the display is in standby mode. See Subsection 5.
7.7 Position the electrode within 3 - 5mm of the work.
7.8 Press the torch switch, after 0.5 second gas pre-ow time the arc will strike at the current set.
7.9 Release the torch switch to initiate the slope-down time after which the arc will go o and the gas post
purge time will commence.
8. TIG Welding with 4 Stoke Torch Switch (4T) and HF Start - See Figure 9
%I
Switch
22
Amps
Arc
Strike
A
2
Gas
on
Torch
On O
Slope Down
Time t
On O
Figure 9 - TIG 4T Operation
2
Crater
Current
Arc
O
Post
Purge
Time
Page 23
SECTION 5 OPERATION
CONTROLS & OPERATION (con't.)
8.1 Set the process/mode selector to TIG 4T and press the HF ON key to select HF start.
8.2 Set the desired welding current with the main setting control A.
8.3 Press the SL slope up/down key once to adjust the down slope (DS displayed in V window).
Press the SL slope up/down key twice to adjust the up slope (US displayed in V window).
Use the encoder knob to adjust the slope time, 0.1 to 10 seconds.
8.5 Set the required gas post purge time (0.2-30 secs) using the PG post gas key and main setting control.
8.6 If required choose AC process and/or Pulse Mode when the display is in standby mode. See Subsections 4
& 5.
8.7 Position the electrode 1/8" (3mm)
8.8 Release the switch and the arc will strike and the welding current will slope up to the value set by the current control A.
8.9 Press and release
in the time set in 7.3 above.
9. GTAW (TIG) Spot Welding (2 Stroke Torch Switch and HF Start) - See Figure 10
9.1 Set the process/mode selector to •••t.
9.2 Set the process/mode to TIG 2T and press the HF ON key to select HF start.
9.3 Set the spot welding time (0.1-10 secs) using •••t spot time key and main setting control .
9.4 Set the required gas post purge time (0.2-30 secs) using the PG post gas key and main setting control.
9.5 Position the electrode 1/8" (3mm) from the work.
current.
Figure 10 - GTAW (TIG) Spot Welding
23
Page 24
SECTION 5 OPERATION
SECTION 5 OPERATION
CONTROLS & OPERATION (con't.)
10. GTAW (TIG) Welding with Manually Sequenced Pulsing - See Figure 11
Figure 11 - TIG Lift Arc Mode
10.1 Set the process to TIG mode using the mode selector key.
10.2 Set the desired "peak" welding current using the main setting control.
10.3 Set the slope-down time, nal/background current and post-purge gas time using the SL, FC and then PG
time keys respectively together with the main setting control as necessary. See above.
10.4 Position the electrode 1/8" (3mm) from the work. Press the torch switch to initiate the gas ow.
10.5 On releasing the torch switch the arc will strikes (assuming HF mode selected) and the current will up-slope
to its peak/main value. Momentary operation (press & release) of the torch switch will now step the current
back to its base level. Repeated momentary operations will alternately step the current from base to peak
levels and back as required for the application.
10.6 To stop welding press and hold the torch switch when the current is at its peak level. The current will now
slope down to its base or nal current level (per the slope-down time as set above) and then remain at this
level until the torch switch is released when the post gas purge will run.
24
Page 25
SECTION 5 OPERATION
SECTION 5 OPERATION
may result in the tungsten point breaking o and transferring to the weld metal. Equally, using a large tungsten
OPTIMIZING TIG WELDING PERFORMANCE
1. Tungsten Electrode Types
ESAB recommends the use of either lanthanated or ceriated tungstens for both AC and DC applications.
Either type is suitable for optimum arc striking and stable performance.
In the past, for AC TIG applications, pure tungsten would be used. Not the case for these new Heliarc ACDC
Square Wave Inverter machines due to the new enhancements in Waveform/Balance control.
Lanthanated or ceriated tungstens can be used for both DC and AC TIG modes due to their higher current
capacity and offer improved performance by maintaining a point in highly "unbalanced" AC conditions.
2. Tungsten Tip Preparation - See Figure 12
For AC and DC TIG the tungsten electrode tip should be straight ground. Radial grinding tends to cause arc wander
and
at low currents by excessively sharpening the tip may result in tip break-o problems.
Figure 12 - Tungsten Preparation
25
Page 26
SECTION 5 OPERATION
SECTION 5 OPERATION
OPTIMIZING TIG WELDING PERFORMANCE (con't.)
3. Maximum Current Ratings for Tungsten Electrodes
1/16 3/32" 1/8"
DC 150A 240A 380A
AC Balanced 60A 100A 150A
4. AC GTAW (TIG) Welding Using FC-5C Foot Control
Unlike other AC TIG equipments the Heliarc AC/DC 281i, 283i and 353i do not use continuous HF to maintain the
AC TIG arc. Once the arc is struck the HF generator is turned o and will not re-energize unless the arc voltage
rises to above 40V or until the torch switch/foot control is reoperated . This feature means that the likelihood of
electrical interference from the welding equipment is greatly reduced.
When using a large and cold tungsten the very low starting current that would normally occur when using a
foot control can on occasion result in poor arc stability until the current is raised to a reasonable level and the
tungsten is hot. To prevent this the power source has an "A
" control enabling the minimum current as set by
min
the remote foot control to be independently preset, see CONTROLS & OPERATION section 2. Recommended
minimum AC current settings, according to tungsten diameter, are as follows:
1/16" (1.6mm) 10A
3/32" (2.4mm) 20A
1/8" (3.2) 30A
If at the end of welding it is required to slope out the current below the level set by the "A
" control, a short nal
min
slope-out time can be set using the T2 up/down keys, see CONTROLS & OPERATION section 6, usually around
1 second is adequate. This will continue the slope down after the pedal has been fully released lling in any
residual crater.
26
Page 27
SECTION 5 OPERATION
SECTION 5 OPERATION
Ammeter
Final Current (A)
AC
Mode
Display
AC-DC Pulse
Frequency (Hz)
AC Frequency (Hz)
AC Balance (%)
Display
Pulse Duty Cycle
Voltmeter
On/Off
Indicator
AC Mode
AC
Frequency
AC
Balance
Main
Knob
Adjustment
Fault
Indicator
Over Temp
Indicator
Output ON
281i, 283i & 353i AC/DC
®
Indicator
AC Power
Control panel
Heliarc
Select
Process
Panel/
Remote
Select
High
Start
Frequency
27
Page 28
SECTION 5 OPERATION
SECTION 5 OPERATION
together
Program Mode
Press and hold
Store
Program
Pulse
Mode
On/Off
Time
Flow Gas
Pre &Post
Re-Call
Program
281i, 283i & 353i AC/DC
®
SMAW
Control panel
Heliarc
(MMA/Stick)
Mode
2T Trigger
Mode
4T Trigger
TIG Spot
Mode
Dual Schedule
Current (A)
Final Current
Pulse Background
Time
Time
Slope
Down
Slope
Up/Down
*
28
*Heliarc 281i is available with adjustable
slope down time only.
Page 29
SECTION 5 OPERATION
SECTION 5 OPERATION
5. Front Control Panel Description and Parameters (con't.)
6
5
7
8
9
10 11
12
4
3
2
1
13
14 15
16
Front Control Panel - Heliarc 281i, 283i and 353i AC/DC
17
19
24
23
22
20
21
18
29
Page 30
SECTION 5 OPERATION
5. Front Panel Description and Parameters (con't.)
1. LED Voltage input - The LED is lit when there is presence of input voltage.
2. LED Voltage output - The LED is lit when there is presence of output voltage (in Tig mode only when you
press the trigger).
3. LED Thermal Protection / Failure - The LED is lit when the machine achieves the duty cycle or there is a failure.
4. Display Voltage / Other Adjustments - The display shows the output voltage during the stand-by and the
real voltage during the welding.
5. Display Amper / Other Adjustments - The display shows the set current during the stand-by and the real
amperage during the welding.
6. AC button - The button activates the AC mode for AC welding and the LED is lit. The display shows the
wording TIG - AC.
7. Frequency Encoder - The encoder adjusts the AC frequency from 20-200 Hz. The value is shown on the
Display A (5). During the operation of adjustment the LED AC Mode is blinking.
8. Pulse Button - The button activates the Pulsing DC and AC function. In DC you can pulse from 0-300Hz in
AC from 0-2Hz. The duty in Pulse is also adjustable from 30-65%. The values are set with the encoder Amper
(14).
9. Balance Encoder - The encoder adjusts the balance of the AC from 10-90% of the set current. The value is
shown on the Display V(4).
10. Pulse LED - The LED is lit when the Pulse Button (8) is pressed and the Pulse function in ON. During the
Frequency and Duty adjustment the LED is blinking.
11. Pre-Post Gas Button - This button adjust both Pre-gas and Post-gas. By pressing the button the display V
shows PRE (pre-gas) or POS (Post gas). Adjust the Pre-gas or Post gas with the Amper Encoder (14) from 0.530 seconds.
12. Final/Base Current button - This button adjust both Base Current and Final Current. By pressing the button
the display A shows the value in %. Adjust the Final/Base current with the Amper Encoder (14) from 10-90%
of the main welding current.
13. Slope Up/Down Button - This button adjust the slope down time. By pressing the button the Display A
shows the value in seconds. Adjust the slope down time with the Amper Encoder (14) from 0.1-10 seconds.
Heliarc 281i is available with adjustable slope down time only.
14. Main Encoder - Encoder for welding current and other adjustments.
15. HF LED - The LED is lit when the HF start is activate.
16. HF button - This button turns on the HF.
30
Page 31
SECTION 5 OPERATION
5. Front Panel Description and Parameters (con't.)
17. Remote Control Button - This button sets the remote control function. The Display A shows the maximum
current. By pressing the button the LED is blinking and adjust the minimum current. The Display V shows
MIN and Display A the value from 0-100 Amp. Adjust the values with the Amper Knob (14). Press the but-
ton for three seconds to deactivate Remote Control mode.
18. LED Remote - The LED is lit when the remote is on and is blinking when the minimum current is adjusted.
19. Select Mode Button - This button selects the welding modes.
20. GTAW Tig 4 Stroke / Repeat - With this function the operator can change from the main set current to the
base current values by pressing the torch trigger quickly.
21. Spot Time Welding - With this function the operator decide a certain time of welding. The Display A shows
the time. The Amper Knob (14) changes the time. The amperage is the one set in GTAW Tig mode.
22. GTAW Tig 4T Mode
23. GTAW Tig 2t Mode
24. SMAW Stick Mode - On stick mode the Arc-Force and Hot-Start are adjustable. By pressing the button
select mode (19) enter in a sub-menu to adjust Arc-Force (0-50%) and Hot Start (0-50%) with the Amper
knob (14).
6. Additional Features
a) GTAW Tig Hot-Start in AC Mode - It is possible to adjust the Hot-start in AC welding from 0-35% of the
Welding Current. In any of the Tig modes (20,21,22,23) by pressing the Select Mode button (19) enter in a
sub-men to adjust the Hot-Start.
b) Welding Programs - The Heliarc allows to store 60 welding programs.
Storing programs:
1. Press both Prg Mode Enter/Exit buttons (pulse and gas buttons) (10,11).
2. Select your program from 1 to 60 using the Main Control Knob.
3. Press and hold the Store Prg. button (base/nal current) (12) until Unit signals with 1 beep, pause,
then 4 beeps. Prg is stored and Exits to Stand by mode.
Recalling the welding programs:
1. Press both Prg Mode Enter/Exit buttons (pulse and gas buttons) (10,11).
2. Select the program you want to recall.
3. Press the Set Prg. button for 3 seconds (slope down) (13).
4. Unit signals with 1 beep, short pause, then 1 beep signaling prg. has been recalled.
with all parameters previously set on that program.
31
Page 32
SECTION 5 OPERATION
SECTION 5 OPERATION
AC
Mode
DC
Mode
Pulse
Flow
Pre/Post
The Table below list the five Modes and the Functions that are available in
each of the modes for the Heliarc 281i, 283i, and 353i power supplies
Final
Current
Time
Slope
Freq
High
Start
Min
Current
Control
Remote
MODE
Yes Yes NA NA NA NA NA Yes Yes
STICK
HS/AF
Yes Yes Yes Yes NA Yes Yes Yes Yes
TIG
Tig
Yes Yes Yes Yes Yes Yes Yes Yes Yes
Dual
Schedule
Yes Yes Yes Yes Yes Yes Yes Yes Yes
Tig
2 Stroke
4 Stroke
Yes Yes Yes NA NA Yes Yes Yes Yes
Tig
Spot
Modes & Functions
32
Page 33
SECTION 5 OPERATION
SECTION 5 OPERATION
Sequential
5 Modes
1
Operation Mode Selection
Quick Set Up
Stick w/ Hot Start
& Arc Force
Tig - Two Stroke
Tig - Four Stroke
Tig - Spot Mode
Tig - Dual Schedule
Press Select Mode Button Repeatedly until the Desired
Mode is Selected (Indicator illuminates ON)
Each time the Select Mode Button is pressed, the Mode
Indicator Sequences One Position Down until it Reaches
Bottom. Then it returns to the top Position and Starts Over.
1
Function Control Procedure Range
Operation Mode
33
Page 34
SECTION 5 OPERATION
SECTION 5 OPERATION
2
ON - OFF
Press Select Mode Button Repeatedly until the Stick
Indicator illuminates (ON)
0 – 50 Percent of
Current Setting
Once in Stick Mode, Press and hold Select Mode Button
until HS is displayed in the V Display Window. Adjust
main current control to set Hot Start.
0 – 50 Percent of
Current Setting
Once in Stick Mode, Press and hold Select Mode Button
until HS is displayed in the V Display Window then
press it once more. Adjust the main current control to
set Arc Force.
Stick (SMAW) Mode
Quick Set Up
34
1
2
2
1
1
1
1
Function Control Procedure Range
Stick (SMAW) Mode ON
Hot Start
Arc Force
Page 35
SECTION 5 OPERATION
SECTION 5 OPERATION
ON - OFF
2
4
1
4
Press Select Mode Button Repeatedly until the Tig
Two Stroke Mode Indicator illuminates (ON)
1
Function Control Procedure Range
2
Tig (GTAW) Two Stroke Mode with Remote Switch
Quick Set Up
Tig Two Stroke Mode
Down Slope Time Press and Adjust to desired time .1 to 10 Seconds
35
Page 36
SECTION 5 OPERATION
SECTION 5 OPERATION
ON - OFF
2
4
1
4
Press Select Mode Button Repeatedly until the Tig
Two Stroke Mode Indicator illuminates (ON)
1
Function Control Procedure Range
2
Tig (GTAW) Two Stroke Mode with Foot Control
Quick Set Up
36
Tig Two Stroke Mode
Down Slope Time Press and Adjust to minimum time Minimum
Page 37
SECTION 5 OPERATION
3
2
4
ON - OFF
4
FourStroke Mode Indicator illuminates (ON)
Press Select Mode Button Repeatedly until the Tig
10 to 90 % of Main A
4
4
Tig (GTAW) Four Stroke Mode
Quick Set Up
1
Function Control Procedure Range
1
Tig Four Stroke Mode
2
Down Slope Time Press and Adjust to desired time .1 to 10 Seconds
2
Up Slope Time Press twice and Adjust to desired time 1 to 10 Seconds
3
Final Current Level Press and Adjust to desired current level
37
Page 38
SECTION 5 OPERATION
2
Sequence
Press Select Mode Button Repeatedly until the Tig Spot
Min to Max Output
Current
Mode Indicator illuminates (ON)
Set Spot Weld Current Level in Normal Tig Mode then
reselect TIG Spot Mode with the Mode Select Button
Tig (GTAW) Spot Mode
Quick Set Up
38
1
1
Function Control Procedure Range
Tig Spot Mode ON
2
Spot Time Adjust Spot Time in the A Display Window .1 – 10 sec
2
Spot Weld Current Level
Page 39
SECTION 5 OPERATION
1
2
3
1
2
10% to 90% Electrode
Negative (Penetration)
3
Press and HOLD for three seconds to turn AC
ON - OFF
Mode OFF
1
AC Mode
Quick Set Up
Function Control Procedure Range
AC Mode ON Press to turn AC Mode ON ON - OFF
AC Frequency Adjust to desired Frequency 20 to 200 Hz.
AC Waveform Balance Adjust to desired Balance
AC Mode OFF
39
Page 40
SECTION 5 OPERATION
10% to 90% of Peak
Setting
(Frequency / Duty
Cycle)
1
3
2
Pulse Operation Continued on Next Page
1
Function Control Procedure Range
2
3
Pulse Mode – Peak/Background
Quick Set Up
40
Pulse Mode ON Press to turn Pulse Mode ON ON - OFF
Pulse Peak Current Adjust to desired Peak Current Level Min to Max of Machine
Pulse Background Current Adjust to desired Background Current Level
Page 41
SECTION 5 OPERATION
SECTION 5 OPERATION
Frequency / Duty Cycle
AC Mode = .4 to 2 Hz.
DC Mode = .4 to 300 Hz.
1
30% to 65% Peak Width
ON - OFF
Pulse Mode – Frequency/Duty Cycle
Quick Set Up
2
Function Control Procedure Range
With Pulse ON, Press to toggle between “Fre”
(Frequency) and “dut” (Duty)
1
Pulse Frequency / Duty
Cycle
2
1
Pulse Frequency Adjust to desired Pulse Frequency (Pulses / Sec)
Adjust to desired Duty Cycle (Percent of Peak Time vs
Background Time)
2
1
1
Pulse Duty Cycle
Press and HOLD for three seconds to turn Pulse Mode
OFF
1
Pulse Mode OFF
41
Page 42
SECTION 5 OPERATION
SECTION 5 OPERATION
Enter - Exit
1 through 60
Programs
1
1
3
4
2
Press and Hold both Buttons for Three Seconds. Unit will
Display Prg and Program Number.
1
Function Control Procedure Range
2
Press and Hold Three Seconds. Unit Beeps Four Times to
Signal Completion of Storage
3
Press and Hold Three Seconds. Unit Flashes Display to
Signal Completion of Program Recall.
4
Store & Recall Programs
Quick Set Up
42
Program Mode
Program (Parameter Set) Adjust to desired Program Number
Store Program
Recall Program
Page 43
SECTION 5 OPERATION
Pre-ow .1 to 2.5 Sec
Post-ow .5 to 30 Sec
32
5
1
Function Control Procedure Range
1
5
2
5
2
5
Press and Adjust to desired time
3
General Functions
Quick Set Up
HF Start (Tig Modes Only) Press ON - Press OFF ON - OFF
Down Slope Time Press and Adjust to desired time .1 to 10 Seconds
Up Slope Time Press twice and Adjust to desired time 1 to 10 Seconds
Pre & Post (Press Once)
Gas Flow Time (Press Twice)
43
Page 44
SECTION 6 MAINTENANCE
6 MAINTENANCE
6 MAINTENANCE
6 MAINTENANCE
7. Fill up the cooling unit with coolant to the maximum level.
8. Put the cooling unit in position and connect it.
6.1 Overview
Regular maintenance is important for safe, reliable operation.
Only personnel with the appropriate electrical skills (authorized staff) may remove safety
plates.
6.2 Power source
Check regularly that the welding power source is not clogged with dirt. Clogged or blocked
air inlets and outlets can result in overheating.
How often and which cleaning methods apply depend on:
• the welding process
• the arc times
• the environment
• the surrounding environment
It is normally sufficient to blow down the power source with dry compressed air (reduced
pressure) once a year.
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.
6.3 Welding torch
A regular programme of care and maintenance reduces unnecessary and expensive
downtime.
Each time a wire bobbin is changed, the welding torch should be removed from the power
source and blown clean with compressed air.
The wire end must not have sharp edges when inserted into the wire liner.
For detailed information see instruction manuals for welding torches.
6.4 Cooling unit
For the cooling unit it is sufficient to keep the inside clean. A dusty environment requires a
more frequent cleaning.
WARNING!
Before any actions are taken, disconnet the cooling unit from the mains power
supply (disconnect the ILME 4-way connector from the power source).
To clean the cooling unit do the following:
1. Disconnect and remove the cooling unit from the power source.
2. Remove all the coolant from the cooling unit.
3. Clean the inside of the cooling unit with compressed air, not higher than 3 bar.
4. Check that all the electrical connections are tightened.
5. Check that all the hydraulic connections are tightened.
6. Replace damaged or worn parts.
44
Page 45
SECTION 6 MAINTENANCE
6 MAINTENANCE
7. Fill up the cooling unit with coolant to the maximum level.
8. Put the cooling unit in position and connect it.
6.5 Fill up the cooling unit with coolant
To fill up the cooling unit with coolant do the following:
1. Turn of the cooling unit and the power source.
2. Disconnect the cooling unit connector from the power source.
3. Remove the safety bolt (1).
4. Carefully pull out the cooling unit (2), enough to access the coolant tank.
5. Fill up the cooling unit with coolant to the maximum level.
6. Carefully push back the cooling unit and fasten it with the safety bolt (1).
45
Page 46
SECTION 6 MAINTENANCE
SECTION 7 WARRANTY
WARRANTY
ESAB oers a full, normally on-site, guarantee on all its welding and cutting equipment. The Heliarc AC/DC 281i,
283i and 353i power sources are guaranteed for a period of 36 months from date of purchase. If during this
period the product proves defective due to incorrect design, materials or workmanship, ESAB or its authorized
Service Center will, free of charge, repair or at the discretion of the company replace the product or its
defective parts.
Please see complete Warranty Statement in the ESAB Standard Terms and Conditions publication.
This guarantee excludes:
1. Normal wear and tear of consumable parts, electrodes, nozzles, motor brushes, relay/contactor contacts etc.
2. Damage resulting from misuse, accident, lack of maintenance, incorrect installation or misapplication.
3. Repairs carried out by non-authorised personnel or the use of non ESAB replacement parts.
4. Loss of use of the product and other incidental or consequential costs incurred by the purchaser.
46
Page 47
SECTION 7 WARRANTY
47
Page 48
ESAB Welding & Cutting Products, Florence, SC
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns
B. ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specications Equipment Recommendations
D. LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status
F. WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site oers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
Loading...