ESAB Heliarc 353iAC/DC, Heliarc 283iAC/DC, Heliarc 281iAC/DC Operating Manual
HELIARC AC/DC
HELIARC AC/DC
281i, 283i & 353i
281i, 283i & 353i
Operating Manual
0558 012079 10/2014
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!
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
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
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.
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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.
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
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°
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
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)
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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
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
SECTION 4 ASSEMBLY
SECTION 4
ASSEMBLY
TROLLEY ASSEMBLY fig. 4-1
13
ASSEMBLY
SECTION 4 ASSEMBLY
TROLLEY ASSEMBLY fig. 4-2
14
SECTION 4 ASSEMBLY
ASSEMBLY
POWER SOURCE TO TROLLEY ASSEMBLY fig. 4-3
15
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