ESAB Heliarc 283i AC/DC, 353i AC/DC, Heliarc Cooling Unit Instruction manual

Heliarc283iAC/DC
Heliarc353iAC/DC
Heliarccoolingunit

Instruction manual

0463 369 001 GB 20160105 Valid for: 283i=S2733450468 353i=S2733450508

Coolingunit=S2733450427

TABLE OF CONTENTS

1 SAFETY ................................................................................................................ 5

2 INTRODUCTION...................................................................................................7

2.1 Overview ............................................................................................................... 7

2.2 Equipment............................................................................................................. 7

3 TECHNICAL DATA ............................................................................................... 8

4 INSTALLATION................................................................................................... 10

4.1 General................................................................................................................ 10

4.2 Lifting instructions.............................................................................................10

4.3 Location .............................................................................................................. 10

4.4 Mains supply ...................................................................................................... 11

5 OPERATION ....................................................................................................... 13

5.1 Overview ............................................................................................................. 13

5.2 Connections and control devices power source ............................................13

5.3 Quick set up........................................................................................................ 16

5.3.1 Operation mode selection ................................................................................16

5.3.2 Stick (SMAW) mode ......................................................................................... 16

5.3.3 TIG (GTAW) two stroke mode with remote switch ........................................... 17

5.3.4 TIG (GTAW) two stroke mode with foot control................................................ 17

5.3.5 TIG (GTAW) four stroke mode ......................................................................... 17

5.3.6 TIG (GTAW) spot mode.................................................................................... 18

5.3.7 AC mode .......................................................................................................... 18

5.3.8 Pulse mode - Peak/Background....................................................................... 19

5.3.9 Pulse mode - Frequency/Duty cycle ................................................................ 19

5.3.10 Store and recall programs................................................................................20

5.3.11 General functions .............................................................................................21

5.3.12 Remote control - On/Off/Minimum ................................................................... 21

5.4 Sub menu power source ...................................................................................21

5.5 Main functions power source ...........................................................................22

5.6 TIG welding information .................................................................................... 24

5.7 Power source overheated ................................................................................. 25

5.8 Connections and control devices cooling unit ...............................................25

5.9 Starting up the cooling unit .............................................................................. 26

6 MAINTENANCE.................................................................................................. 28

6.1 Overview ............................................................................................................. 28

6.2 Power source...................................................................................................... 28

6.3 Welding torch .....................................................................................................28

6.4 Cooling unit ........................................................................................................28

6.5 Fill up the cooling unit with coolant.................................................................29

7 FAULT TRACING................................................................................................ 30

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TABLE OF CONTENTS

8 ORDERING SPARE PARTS............................................................................... 32

DIAGRAM ..................................................................................................................33

WELDING TABLES ...................................................................................................35

ORDERING NUMBERS .............................................................................................37

ACCESSORIES .........................................................................................................38

Rights reserved to alter specifications without notice.

0463 369 001 © ESAB AB 2016

1 SAFETY

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 observed in addition to the standard regulations that apply to
the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.

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

○ its operation

○ location of emergency stops

○ its function

○ relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorised person is stationed within the working area of the equipment when it

is started up

○ no-one is unprotected when the arc is struck or work is started with the equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could

become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

○ Work on high voltage equipment may only be carried out by a qualified electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

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1 SAFETY

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

• Install and earth the 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!

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

Read and understand the instruction manual before
installing or operating.

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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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2 INTRODUCTION

2 INTRODUCTION

2.1 Overview

The Heliarc 283i and 353i AC/DC are welding power sources intended for MMA and TIG
welding. The Heliarc 283i is rated up to 280 A and the Heliarc 353i up to 350 A.

A 230 V AC auxiliary supply is available, accessed through the rear panel, when using the
Heliarc cooling unit.

The Heliarc cooling unit is used with the Heliarc 283i and 353i AC/DC. It distributes 2
litres/min, with the torch connected, with a power of 60 W.

A trolley is an option available for the power sources.

ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.

2.2 Equipment

The power sources comes with:

• return cable with clamp

• mains cable

• gas hose

• instruction manual

The cooling unit comes with:

• instruction manual

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3 TECHNICAL DATA

3 TECHNICAL DATA

283i AC/DC 353i AC/DC

Mains voltage 400 V ±10%,

3~ 50/60 Hz

400 V ±10%,
3~ 50/60 Hz

Mains cable 4G4 mm 4G4 mm

Line fuse min 25 A min 25 A

Setting range GTAW/TIG AC/DC 4 - 280 A 4 - 350 A

Maximum output

GTAW/TIG, AC/DC 280 A at 100% 350 A at 45%

Gas pre-flow 0.5 - 30 sec 0.5 - 30 sec

Slope up/slope down 0.1 - 10 sec 0.1 - 10 sec

Gas post-flow 0.5 - 30 sec 0.5 - 30 sec

Frequency AC 20 -200 Hz 20 - 200 Hz

AC balance 10 - 90% 10 - 90%

DC Pulse mode frequency 0.4 - 300 Hz 0.4 - 300 Hz

AC Pulse mode frequency 0.4 - 2 Hz 0.4 - 2 Hz

Pulse duty (pulse

time/background time) 30 - 65% 30 - 65%

Background current 10 - 90 A 10 - 90 A

Slope down time 0.1 -10 s 0.1 - 10 s

Start/crater current (4-stroke) 10 - 90 % 10 - 90 %

Post purge time 0.5 - 30 s 0.5 - 30 s

Remote start point current 4 - 100 A 4 - 100 A

Open circuit voltage max 68 V 68 V

Power factor at 100 % TIG mode 0.75 0.8

Setting range SMAW/MMA 4 - 280 A 4 - 350 A

Maximum output SMAW/MMA, AC/DC

20% duty cycle - 350 A

40% duty cycle 280 A -

KVA GTAW/TIG 11 14.5

KVA SMAW/MMA 14.2 19

Enclosure class IP 21S IP 21S

Dimensions l × w × h 600 × 300 × 620 mm 600 × 300 × 620 mm

Weight without cooling unit 50 kg 50 kg

Weight trolley 35 kg 35 kg

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration
by solid objects or water.

Equipment marked IP21 is intended for indoor use.



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3 TECHNICAL DATA

Heliarc cooling unit

Mains voltage 400 V ±10%, 1~, 50/60 Hz

Maximum power supply current 0.75 A

P1l/min 0.5 kW

Cooling power 60 W

Coolant "ESAB's ready mixed coolant, see the

"ACCESSORIES" chapter.

Coolant quantity 5 l (delivered with approx. 2.5 l)

Pressure max 0.35 MPa

Maximum water flow 2.0 l/min

Operating temperature -10° to +40°C

Transportation temperature -20° to +55°C

Dimensions (l × w × h) 475 × 310 × 250 mm

Weight empty 14 kg

Enclosure class IP21

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration
by solid objects or water.

Equipment marked IP21 is intended for indoor use.

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4 INSTALLATION

4 INSTALLATION

4.1 General

The installation must be carried out by a professional.

4.2 Lifting instructions

Lifting the power source by hand.

WARNING!

The power source weighs 50 kg (110 lbs).

WARNING!

Be two persons and lift the power
source by using the two handles.

Lifting the power source using hoist and strap.

WARNING!

Lift the power source by using the
eyebolt. Keep the power supply
as horizontal as possible.

WARNING!

Secure the equipment ­particularly if the ground is
uneven or sloping.

4.3 Location

Position the welding power source such that its cooling air inlets and outlets are not
obstructed. Make sure that no deposits or dust goes into the power source. Prevent impacts,
rubbing and exposure to dripping water, excessive heat sources or any unusual situations.

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4 INSTALLATION

4.4 Mains supply

NOTE!
Mains supply requirements

This equipment complies with IEC 61000-3-12 provided that the short-circuit
power is greater than or equal to S

supply and the public system. It is the responsibility of the installer or user of the
equipment to ensure, by consultation with the distribution network operator if
necessary, that the equipment is connected only to a supply with a short-circuit
power greater than or equal to S

scmin

TECHNICAL DATA chapter.

CAUTION!

Make sure that the ON/OFF switch is set to OFF (0) before making any electrical
connections between the power source and the 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 mains distribution panel must comply with the
regulations in force in the country of use. The mains supply system must be of the industrial
type.

at the interface point between the user's

scmin

. Refer to the technical data in the

A protective earth connection must be made in accordance with regulations. The power
source must be correctly connected to earth to protect the operator. It is indispensable to
provide good earthing by means of the yellow-green lead in the power cable, to prevent
discharges due to accidental contacts with earthed objects. The chassis, which is conductive,
is electrically connected with the earth lead. If the equipment is not correct connected with
the earth lead it may cause electric shocks which are dangerous for the operator.

The power source works at mains voltages differing by 20% from the rated mains (400 V
rated, minimum voltage 320 V, maximum voltage 480 V).

Heliarc 283i AC/DC Heliarc 353i AC/DC

Mains voltage 400 V, 3~ , 50/60 Hz 400 V, 3~ , 50/60 Hz

Fuse 20 A 25 A

Connection instruction cooling unit

Make sure that the Heliarc is correctly connected to earth to protect the operator. It is
indispensable to provide good earthing by means of the yellow-green lead in the power
cable, to prevent discharges due to accidental contacts with earthed objects.

The chassis, which is conductive, is electrically connected with the earth lead. If the
equipment is not correct connected with the earth lead it may cause electric shocks which
are dangerous for the operator.

The cooling unit must be connected to the power source with the special ILME multipole plug
supplied. Make sure that the power source is turned off and disconnected from the mains
power supply before making any electrical connections between the cooling unit and the
power source.

If the cooling unit is going to be connected to three phase mains voltage, replace the special
ILME 4-way plug with a three phase plug. Connect the supply wires to only two of the
contacts (black-brown) of the plug and the earth led (yellow/green) to the earth contact.

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4 INSTALLATION

Connect the cooling unit to the power source

1. Remove the screws (1), the safety bolt (2) and the door panel (3).

2. Remove the plastic cap at the rear of the trolley chassi.

3. Pull the cooling unit input cable through the hole at the rear of the trolley chassi.

4. Fasten the input cable with the screws (4).

The Heliarc 353i AC/DC is already equipped with a connector to connect the cooling unit. To
start the cooling unit it is necessary to switch on both the power source and the cooling unit.

Hydraulic connection

Connect the water delivery pipe of the torch to water output coupling on the cooling unit.
Connect the water return pipe of the torch to the water input coupling on the cooling unit.

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5 OPERATION

5 OPERATION

5.1 Overview

General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!

5.2 Connections and control devices power source

Front connections

Type Connection PIN Description

YES A Gas

TIG

Type Connection PIN Description

MMA





TIG TORCH B Negative

YES D-F Pin

EARTH CLAMP E Positive

NO A Gas

EARTH CLAMP B Negative

POSSIBLE REMOTE F Pin

ELECTRODE E Positive

NOTE!

Connection D, 2 pin cannon, can be used for either analogue foot control or
torch.

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5 OPERATION

Cooling unit connection

4 Pin

PIN Description

connector

1 Power supply common

Power supply

2 Power supply 115/230 V AC

3 Power supply 400 V AC

GRD 4 Chassis common

14 pin connector

14 Pin

PIN Description

connector

A Torch switch

Torch trigger

B Torch switch

E Remote control circuit common

F +5 V DC input remote control

Remote control

G +5 V DC output remote control

D +5 V DC output remote control

GRD H Chassis common

2 pin connector

2 Pin

PIN Description

connector

A Torch switch

B Torch switch

Torch trigger

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5 OPERATION

Front panel

Item Denomination

1 Power source live LED

2 Welding enabled LED

3 Over temperature LED

4 Volt display

5 Ampere display

6 AC mode button

7 AC mode LED

8 AC frequency setting, 20-200 Hz

9 AC balance setting, 10-90%

10 Pulse mode button (0.4-300 Hz DC, 0.4-2 Hz AC)

11 Pulse mode LED

12 Pre-gas (0.1-2.5 sec) Post-gas (0.1-30 sec) button

13 Base current button (10-90%)

14 Slope up/down button (slope up 0.1-10 sec, slope down 0.1-10 sec)

15 Encoder knob for current setting and other settings

16 HF LED

17 HF button

18 Select mode button

19 Remote control button

20 Remote button LED

21 Mode TIG dual schedule LED

22 Mode TIG spot LED

23 Mode TIG 4 stroke LED

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5 OPERATION

Item Denomination

24 Mode TIG 2 stroke LED

25 Mode Stick LED

5.3 Quick set up

5.3.1 Operation mode selection

Press the select mode button (1) repeatedly until the desired mode is selected, indicated by
a green LED.

5.3.2 Stick (SMAW) mode

1. Press the select mode button (1) repeatedly until the Stick w/Hot start & Arc force LED is
lit.

2. Press the select mode button (1) for a few seconds until "HS" is shown in the V display.

3. Set the value for hot start with the encoder knob (2).

4. Press the select mode button (1) for a few seconds unit "HS" is shown in the V display.

5. Press the select mode button (1) again, "AF" is shown on the V display.

6. Set the value for the arc force with the encoder knob (2).

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5 OPERATION

5.3.3 TIG (GTAW) two stroke mode with remote switch

1. Press the select mode button (1) repeatedly until the TIG two stroke LED is lit.

2. Press the slope up/down button (3) and adjust the slope down time.

5.3.4 TIG (GTAW) two stroke mode with foot control

1. Press the select mode button (1) repeatedly until the TIG two stroke LED is lit.

2. Press the slope up/down button (3) and adjust the slope down time with the encoder
knob (2) to the minimum time.

5.3.5 TIG (GTAW) four stroke mode

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5 OPERATION

1. Press the select mode button (1) repeatedly until the TIG four stroke LED is lit.

2. Press the slope up/down button (3) once to adjust the down slope (ds displayed in V
window). Press the slope up/down button (3) twice to adjust the up slope (us displayed in
V window). Use the enconder knob (2) to adjust the slope time, 0.1 to 10 seconds.

3. Press the base current button (4) and adjust the current level (10-90% of main amps)
with the encoder knob (2).

5.3.6 TIG (GTAW) spot mode

1. Press the select mode button (1) repeatedly until the TIG Spot mode LED is lit.

2. Adjust the spot time, shown in A display, with the encoder knob (2).

3. Set the spot welding current level in Normal TIG mode.

4. Press the select mode button (1) repeatedly until the TIG Spot mode LED is lit.

5.3.7 AC mode

1. Press the AC mode button (1) to turn on the AC mode.

2. Adjust the spot time, shown in A display, with the AC frequency button (2).

3. Adjust the balance (10 to 90%) with the AC balance button (3).

4. Press the AC mode button (1) for 3 seconds to turn off the AC mode.

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5 OPERATION

5.3.8 Pulse mode - Peak/Background

1. Press the pulse mode button (1) to turn on the pulse mode.

2. Adjust the peak current level with the encoder knob (2).

3. Adjust the background current level with the base current button (3).

5.3.9 Pulse mode - Frequency/Duty cycle

1. With the pulse mode ON, press the pulse mode button (1) to switch between "FRE"
(frequency) and "DUT" (duty).

2. In "FRE" mode adjust the pulse frequency (AC: 0.4 to 2 Hz, DC: 0.4 to 300 Hz) with the
encoder knob (2).

3. In "DUT" mode adjust the duty (30 to 65% peak width) with encoder knob (2). More duty
= more heat.

4. Press the pulse mode button (1) for 3 seconds to turn off the pulse mode.

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5 OPERATION

Ampere

A = Base current time

B = Pulse time

C = Frequency

The duty is B divided by A in percent.

t

5.3.10 Store and recall programs

60 welding parameters can be stored and recalled.

1. Press both the pulse mode button and pre-gas/post-gas button (1) for 3 seconds. "Prg"
and a program number is shown on the display.

2. Select program number with the encoder knob (2).

3. To store, press the base current button (3) for 3 seconds. The unit beeps 4 times when
the program is stored.

4. To recall, press the slope up/slop down button (4) for 3 seconds. The unit display flashes
when the program is recalled.

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5 OPERATION

5.3.11 General functions

1. Press the HF button (1) to turn on the HF.

2. Press the slope up/down button (2) one time and adjust the slope up time (0.1 to 10
seconds) with the encoder knob (4).

Press the slope up/down button (2) two times and adjust the slope down time (0.1 to 10
seconds) with the encoder knob (4).

3. Press the pre-gas/post-gas button once and adjust the preflow time (0.1 to 25 seconds)
with the encoder knob (4).

4. Press the pre-gas/post-gas button twice and adjust the postflow time (0.5 to 30 seconds)
with the encoder knob (4).

5.3.12 Remote control - On/Off/Minimum

1. Press the remote control button (1) to turn on the remote current.

2. Press the remote control button for 2 seconds and release it.

3. The button remote LED blinks and the display shows "Min".

4. Adjust the remote current with the encoder knob (2).

5. Press the remote control button (1) for 3 seconds to turn off the remote current.

5.4 Sub menu power source

Hot start TIG AC

NOTE!

Hot start TIG AC is only active in TIG below 130 A.

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5 OPERATION

1. Select one of the TIG modes.

2. Press the select mode button for 2 seconds and release it. The LED blinks and the
display shows "HS".

3. Adjust the value of "Hot start", from 0 to 100% of the main welding current set (max 135
A), with the encoder knob.

5.5 Main functions power source

TIG 2-stroke

Ampere

A = Pre gas

B = Arc ON

C = t slope

D = Arc OFF

E = Post gas time

F = Torch trigger ON

G = Torch trigger OFF

t

TIG 4-stroke

Ampere

A = Pre gas

B = Arc ON

C1= t slope up
C2= t slope down

D = Arc off

E = Post gas time

F = Torch trigger ON

G = Torch trigger OFF

H = Torch trigger ON/OFF

t

TIG dual schedule

The TIG dual schedule function allows the operator to use 2 current level switching from the
main and base current by quickly pressing the trigger torch.

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5 OPERATION

Ampere

A = Pre gas

B = Arc ON

C1= t slope up
C2= t slope down

D = Arc OFF

E = Post gas time

F = Torch trigger ON

G = Torch trigger OFF

H = Torch trigger ON/OFF

I = Torch trigger ON

J = Torch trigger OFF

t

TIG AC/DC

When welding in AC/DC it is possible to adjust the AC frequency from 20 to 200 Hz with the
AC frequency button.

I

(A)

OUT

It is also possible to adjust the AC balance from 10% to 90% EN (Electrode Negative) with
the AC balance button. The figure below shows 2 extreme conditions.

Case A: Maximum cleaning, minimum penetration, Tungsten electrode wear out.

Case B: Maximum penetration, minimum cleaning, limited Tungsten electrode wear out.

The best compromise is normally with a balance of 80% and 80 Hz of frequency.

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5 OPERATION

5.6 TIG welding information

Electrode type

For AC/DC and DC welding, Grey Cerium or Gold Lanthanium electrodes are recommended.
In case of change fron AC/DC to DC welding substitute the electrode. A tip is made on the
electrode as shown in the figure below.

The angle varies as the welding current varies. The table below show recommended values.

Angle (°) Welding current

30 5-30

60 - 90 30 - 120

90 - 120 120 - 160

Filler material

Many kinds of material can be treated, however there are som basic rules:

1. The rods of weld material must have the same mechanical and chemical properties as
the material to be welded.

2. It is recommended not to use parts of the base material, as they could contain impurities
due to the work process.

3. If the material used has a different chemical composition, it is advisable to assess the
final characteristics of the joint, both mechanical and anti-corrosive.

Gas

The protection gas normally used is pure argon with a quantity that varies according to the
current used (4-6 l/min).

TIG welding on copper

Due to the properties already described, TIG welding is also excellent for working on
materials with high heat conductivity. The gas used is always argon and, in the case of
copper, the use of a backing support is recommended. Preparation of the edges for welding
copper (flat butt joint).

The electrode used is of the same type described for welding steel, it is prepared as
described above. To prevent possible oxidation in the welded area, weld materials containing
phosphor, silicon and deoxidizing components are used.

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5 OPERATION

5.7 Power source overheated

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.

If the power source is overheated:

• The over temperature LED is lit

• Wait for 10 minutes before starting welding again

5.8 Connections and control devices cooling unit

Front panel

1 Main switch

2 Optical alarm LED

3 Cooling unit ON/OFF

4 Cold water outlet, blue tube on the torch

5 Fuse

6 Sound alarm for lack of water circulation

7 Hot water return, red tube on the torch

ILME 4-way connector

4 Pin

PIN Description

connector

1 Power supply common

Power supply

2 Power supply 115/230 V AC

3 Power supply 400 V AC

GRD 4 Chassis common

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5 OPERATION

5.9 Starting up the cooling unit

NOTE!

At the first start, the cooling unit might alarm due to lack of liquid in the pipes.
Wait a few minutes or turn the cooling unit ON and OFF a couple of times.

NOTE!

The cooling unit alarms if the torch is not connected, damaged or if the liquid
level is to low.

1. Check that the cooling unit is filled with coolant to the maximum level. If not, fill the
cooling unit to the maximum level.

2. Make all the electrical and hydraulic connections.

3. Turn on the power source to feed the cooling unit.

4. Turn on the cooling unit.

5. Make sure that the coolant is circulating through the hydraulic circuit of the torch and
returning to the tank.

6. Check the level of coolant again and top up if necessary.

NOTE!

Check the coolant level regurlarly and top up if necessary.

Lack of coolant

If air get into the pump due to lack of coolant or no coolant, the following can happen:

• the alarm is activated

• the pump sounds loud

• the coolant does not circulate

To solve the problem do the following actions:

1. Make sure that there is coolant in the cooling unit and at the maximum level.

2. Disconnect the torch hose from the hot-water return (red hose).

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5 OPERATION

3. Discharge the torch water into a separate bucket.

4. With the cooling unit on, blow some air into the red coupling.

5. Keep blowing until the water flushes continuously into the bucket from the torch hose and
the pump sounds normal.

6. Turn off the cooling unit and connect the torch hose to the hot water return.

7. Turn on the cooling unit.

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6 MAINTENANCE

6 MAINTENANCE

6.1 Overview

Regular maintenance is important for safe, reliable operation.

Only personnel with the appropriate electrical skills (authorized staff) may remove safety
plates.

CAUTION!

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

6.2 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.

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.

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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).

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7 FAULT TRACING

7 FAULT TRACING

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

Fault tracing power source

Type of fault Corrective action

No arc. • Check that the mains power supply switch

is turned on.

• Check that the mains, welding and return
cables are correctly connected.

• Check that the correct current value is
set.

• Check the mains power supply fuses.

The welding current is interruppted during
welding.

• Check whether the overloading protection
has deployed (indicated on the front).

• Check the mains power supply fuses.

• Check that the return cable is correctly
fastened.

The overheating protection trips frequently. • Make sure that you are not exceeding the

rated data for the power source (i.e. that
the unit is not being overloaded).

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

are correctly connected.

• Check that the correct current value is
set.

• Check that the correct wire or electrode is
used.

• Check the mains power supply fuses.

• Check the gas pressure in the equipment
connected to the power source.

"TRI - ALA" (Trigger Alarm) on display when
power source is turned on.

NOTE!

This error occurs if the torch
trigger is pushed when the power

• Turn off the power source completely.

• Make sure that the torch trigger is not
pushed.

• Check if the torch trigger is damaged.

• Turn on the power source again.

source is started.

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© ESAB AB 2016

7 FAULT TRACING

Fault tracing cooling unit

Type of fault Corrective action

Does not switch on. • Check that the mains power supply switch

is turned on.

• Check the mains power supply fuses.

• Check that the mains, welding and return
cables are correctly connected.

The coolant is not circulating. • Stop the cooling unit immediately, top up

with coolant and make sure that there are
no leaks.

• Free pipes from kinks.

• Make sure that the pipe connections are
correctly installed.

• Check the pump capacity.

Loud noise • Stop the cooling unit immediately, top up

with coolant and make sure that there are
no leaks.

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8 ORDERING SPARE PARTS

8 ORDERING SPARE PARTS

Repair and electrical work should be performed by an authorised ESAB service technician.
Use only ESAB original spare and wear parts.

The Heliarc 283i and Heliarc 353i AC/DC are designed and tested in accordance with
international and european standards IEC/EN 60974-1 and IEC/EN 60974-10. On
completion of service or repair work, it is the responsibility of the person(s) performing the
work to ensure that the product still complies with the requirements of the above standard.

The Heliarc cooling unit is designed and tested in accordance with international and
european standard IEC/EN 60974-2. On completion of service or repair work, it is the
responsibility of the person(s) performing the work to ensure that the product still complies
with the requirements of the above standard.

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

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© ESAB AB 2016

DIAGRAM

DIAGRAM

Heliarc 283i AC/DC, Heliarc 353i AC/DC

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© ESAB AB 2016

DIAGRAM

Heliarc cooling unit

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© ESAB AB 2016

WELDING TABLES

WELDING TABLES

Welding table steel

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© ESAB AB 2016

WELDING TABLES

Welding table aluminium

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© ESAB AB 2016

ORDERING NUMBERS

ORDERING NUMBERS

Ordering number Denomination Type Notes

0700 300 701 Welding power source Heliarc 283i AC/DC 400 V

0700 300 702 Welding power source Heliarc 353i AC/DC 400 V

0700 300 703 Cooling unit Heliarc cooling unit

0464 524 010 Spare parts list Heliarc 283i AC/DC,

400 V

353i AC/DC

0464 524 020 Spare parts list Heliarc cooling unit

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© ESAB AB 2016

ACCESSORIES

ACCESSORIES

0558 101 703 Cooling unit

0349 483 296 Cooling liquid GLIDEX-35deg, 5 l

0349 312 925 Cooling liquid GLIDEX-35 deg, 10 l

0700 006 888 Electrode holder with 3 m cable

0558 101 702 Trolley

0558 004 234 FC5C foot control

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© ESAB AB 2016

ACCESSORIES

TIG torches air cooled

0700 300 524

0700 300 529

0700 300 538

0700 300 544

0700 300 552

0700 300 555

TXH 121, 4 m

TXH 121, 8 m

TXH 151, 4 m

TXH 151, 8 m

TXH 201, 4 m

TXH 201, 8 m

TIG Torches water cooled

0700 300 561

0700 300 562

0700 300 563

0700 300 564

0700 300 565

0700 300 566

0700 300 567

0700 300 568

TXH 251w, 4 m, OKC 50

TXH 251 wF, 4 m, OKC 50

TXH 251w, 8 m, OKC 50

TXH 251wF, 8 m, OKC 50

TXH 401w, 4 m

TXH 401w HD, 4 m

TXH 401w, 8 m

TXH 401w HD, 8 m

TIG torches air cooled with built in remote control

0700 300 657

0700 300 661

0700 300 658

0700 300 662

TXH 151, 8 m, wheel remote, 3.64 kg

TXH 151, 8 m, flex wheel remote, 3.64 kg

TXH 201, 8 m, wheel remote, 4.9 kg

TXH 201, 8 m, flex wheel remote, 4.9 kg

TIG torches water cooled with remote control

0700 300 659

0700 300 660

0700 300 663

TXH 251w, 8 m, wheel remote, 2.8 kg

TXH 401w, 8m, wheel remote, 4.56 kg

TXH 251w, 8 m, flex wheel remote, 2.82 kg

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© ESAB AB 2016

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna-Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V.
Heist-op-den-Berg
Tel: [phone]
Fax: [phone]

BULGARIA

ESAB Kft Representative Office
Sofia
Tel: [phone]
Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Vamberk
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Herlev
Tel: [phone]
Fax: [phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel: [phone]
Fax: [phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel: [phone]
Fax: [phone]

ITALY

ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: [phone]
Fax: [phone]

THE NETHERLANDS

ESAB Nederland B.V.
Amersfoort
Tel: [phone]
Fax: [phone]

NORWAY

AS ESAB
Larvik
Tel: [phone]
Fax: [phone]

POLAND

ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Romania Trading SRL
Bucharest
Tel: [phone]
Fax: [phone]

RUSSIA

LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel: [phone]
Fax: [phone]

SPAIN

ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel: [phone]
Fax: [phone]

ESAB International AB
Gothenburg
Tel: [phone]
Fax: [phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

UKRAINE

ESAB Ukraine LLC
Kiev
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem-MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting
Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

AUSTRALIA

ESAB South Pacific
Archerfield BC QLD 4108
Tel: [phone]
Fax: [phone]

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. ESABindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

JAPAN

ESAB Japan
Tokyo
Tel: [phone]
Fax: [phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
USJ
Tel: [phone]
Fax: [phone]

SINGAPORE

ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]

Africa

EGYPT

ESAB Egypt
Dokki-Cairo
Tel: [phone]
Fax: [phone]

SOUTH AFRICA

ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: [phone]

Distributors

For addresses and phone
numbers to our distributors in
other countries, please visit our
home page

www.esab.com

www.esab.com