Heliarc 283i AC/DC
Heliarc 353i AC/DC
Heliarc cooling unit
Instruction manual
0463 369 001 GB 20131114
Valid for: 283i = S2733450468 353i = S2733450508
Cooling unit = S2733450427
TABLE OF CONTENTS
1
SAFETY ................................................................................................................ 5
2
INTRODUCTION ................................................................................................... 8
2.1
Overview ............................................................................................................... 8
2.2
Equipment............................................................................................................. 8
3
TECHNICAL DATA ............................................................................................... 9
4
INSTALLATION................................................................................................... 11
5
4.1
General................................................................................................................ 11
4.2
Lifting instructions............................................................................................. 11
4.3
Location .............................................................................................................. 11
4.4
Mains supply ...................................................................................................... 12
OPERATION ....................................................................................................... 14
5.1
Overview ............................................................................................................. 14
5.2
Connections and control devices power source ............................................14
5.3
Quick set up........................................................................................................ 17
5.3.1
Operation mode selection ................................................................................ 17
5.3.2
Stick (SMAW) mode ......................................................................................... 17
5.3.3
TIG (GTAW) two stroke mode with remote switch ........................................... 18
5.3.4
TIG (GTAW) two stroke mode with foot control................................................ 18
5.3.5
TIG (GTAW) four stroke mode ......................................................................... 18
5.3.6
TIG (GTAW) spot mode.................................................................................... 19
5.3.7
AC mode .......................................................................................................... 19
5.3.8
Pulse mode - Peak/Background....................................................................... 20
5.3.9
Pulse mode - Frequency/Duty cycle ................................................................ 20
5.3.10 Store and recall programs................................................................................ 21
5.3.11 General functions ............................................................................................. 22
5.3.12 Remote control - On/Off/Minimum ................................................................... 22
6
7
5.4
Sub menu power source ................................................................................... 22
5.5
Main functions power source ...........................................................................23
5.6
TIG welding information .................................................................................... 25
5.7
Power source overheated ................................................................................. 26
5.8
Connections and control devices cooling unit ...............................................26
5.9
Starting up the cooling unit .............................................................................. 27
MAINTENANCE .................................................................................................. 29
6.1
Overview ............................................................................................................. 29
6.2
Power source...................................................................................................... 29
6.3
Welding torch ..................................................................................................... 29
6.4
Cooling unit ........................................................................................................ 29
6.5
Fill up the cooling unit with coolant .................................................................30
FAULT TRACING................................................................................................ 31
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© ESAB AB 2013
TABLE OF CONTENTS
8
ORDERING SPARE PARTS ............................................................................... 33
DIAGRAM .................................................................................................................. 34
WELDING TABLES ...................................................................................................36
ORDERING NUMBERS .............................................................................................38
ACCESSORIES .........................................................................................................39
Rights reserved to alter specifications without notice.
0463 369 001
© ESAB AB 2013
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 equpment
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 extinquishing 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. 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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1 SAFETY
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:
•
•
•
•
5 m return cable with clamp
5 m mains cable
gas hose
instruction manual
The cooling unit comes with:
•
instruction manual
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3 TECHNICAL DATA
3
TECHNICAL DATA
Mains voltage
283i AC/DC
353i AC/DC
400 V ±10%,
3~ 50/60 Hz
400 V ±10%,
3~ 50/60 Hz
Setting range GTAW/TIG AC/DC 4 - 280 A
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 - 350 A
4 - 280 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.
Heliarc cooling unit
Mains voltage
400 V ±10%, 1~, 50/60 Hz
Maximum power supply current
0.75 A
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3 TECHNICAL DATA
Heliarc cooling unit
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
High power equipment may, due to the primary current drawn from the mains
supply, influence the power quality of the grid. Therefore connection restrictions
or requirements regarding the maximum permissible mains impedance or the
required minimum supply capacity at the interface point to the public grid may
apply for some types of equipment (see technical data). In this case it is the
responsibility of the installer or user of the equipment to ensure, by consultation
with the distribution network operator if necessary, that the equipment may be
connected.
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.
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.
2.
3.
4.
Remove the screws (1), the safety bolt (2) and the door panel (3).
Remove the plastic cap at the rear of the trolley chassi.
Pull the cooling unit input cable through the hole at the rear of the trolley chassi.
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
TIG
Connection
PIN
YES
A
Gas
TIG TORCH
B
Negative
YES
D-F
EARTH CLAMP
Type
MMA
Description
Connection
E
PIN
Pin
Positive
Description
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
connector
Power supply
GRD
PIN Description
1
Power supply common
2
Power supply 115/230 V AC
3
Power supply 400 V AC
4
Chassis common
14 pin connector
14 Pin
connector
Torch trigger
Remote control
GRD
PIN Description
A
Torch switch
B
Torch switch
E
Remote control circuit common
F
+5 V DC input remote control
G
+5 V DC output remote control
D
+5 V DC output remote control
H
Chassis common
2 pin connector
2 Pin
connector
PIN Description
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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© ESAB AB 2013
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. Keep the slope up/down button (3) pressed and adjust the slope up/down time (0.1 to 10
seconds) with the encoder knob (2).
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. Keep the slope up/down button (3) pressed and adjust the slope up/down time with the
encoder knob (2) to the minimum time.
5.3.5
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TIG (GTAW) four stroke mode
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© ESAB AB 2013
5 OPERATION
1. Press the select mode button (1) repeatedly until the TIG four stroke LED is lit.
2. Keep the slope up/down button (3) pressed and adjust the slope up/down time (0.1 to 10
seconds) with the encoder knob (2).
3. Keep the base current button (4) pressed and adjust the current level (10-90% of main
amps) with the encoder knob (2).
5.3.6
1.
2.
3.
4.
Press the select mode button (1) repeatedly until the TIG Spot mode LED is lit.
Adjust the spot time, shown in A display, with the encoder knob (2).
Set the spot welding current level in Normal TIG mode.
Press the select mode button (1) repeatedly until the TIG Spot mode LED is lit.
5.3.7
1.
2.
3.
4.
TIG (GTAW) spot mode
AC mode
Press the AC mode button (1) to turn on the AC mode.
Adjust the spot time, shown in A display, with the AC frequency button (2).
Adjust the balance (10 to 90%) with the AC balance button (3).
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
t
A = Base current time
B = Pulse time
C = Frequency
The duty is B divided by A in percent.
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
1.
2.
3.
4.
5.
Remote control - On/Off/Minimum
Press the remote control button (1) to turn on the remote current.
Press the remote control button for 2 seconds and release it.
The button remote LED blinks and the display shows "Min".
Adjust the remote current with the encoder knob (2).
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.
IOUT (A)
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.
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
connector
Power supply
GRD
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PIN Description
1
Power supply common
2
Power supply 115/230 V AC
3
Power supply 400 V AC
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.
2.
3.
4.
5.
Make all the electrical and hydraulic connections.
Fill the cooling unit with coolant to the maximum level.
Turn on the power source to feed the cooling unit.
Turn on the cooling unit.
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 regularly ant 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).
0463 369 001
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© ESAB AB 2013
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.
0463 369 001
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© ESAB AB 2013
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.
2.
3.
4.
5.
6.
Disconnect and remove the cooling unit from the power source.
Remove all the coolant from the cooling unit.
Clean the inside of the cooling unit with compressed air, not higher than 3 bar.
Check that all the electrical connections are tightened.
Check that all the hydraulic connections are tightened.
Replace damaged or worn parts.
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© ESAB AB 2013
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.
2.
3.
4.
5.
6.
Turn of the cooling unit and the power source.
Disconnect the cooling unit connector from the power source.
Remove the safety bolt (1).
Carefully pull out the cooling unit (2), enough to access the coolant tank.
Fill up the cooling unit with coolant to the maximum level.
Carefully push back the cooling unit and fasten it with the safety bolt (1).
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© ESAB AB 2013
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.
•
•
•
•
The welding current is interruppted during
welding.
•
•
•
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.
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.
•
•
•
•
"Err" on display in open circuit mode
•
•
•
0463 369 001
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Check the mains power supply fuses.
Check that the voltage on the voltage
selection label on the rear of the power
source is equal to the nominal mains
voltage.
Restart the power source with the main
switch
© ESAB AB 2013
7 FAULT TRACING
Fault tracing cooling unit
Type of fault
Corrective action
Does not switch on.
•
•
•
The coolant is not circulating.
•
•
•
•
Loud noise
0463 369 001
•
- 32 -
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.
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.
Stop the cooling unit immediately, top up
with coolant and make sure that there are
no leaks.
© ESAB AB 2013
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.
0463 369 001
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© ESAB AB 2013
DIAGRAM
DIAGRAM
Heliarc 283i AC/DC, Heliarc 353i AC/DC
0463 369 001
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© ESAB AB 2013
DIAGRAM
Heliarc cooling unit
0463 369 001
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© ESAB AB 2013
WELDING TABLES
WELDING TABLES
Welding table steel
0463 369 001
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© ESAB AB 2013
WELDING TABLES
Welding table aluminium
0463 369 001
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© ESAB AB 2013
ORDERING NUMBERS
ORDERING NUMBERS
Ordering number
Denomination
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,
353i AC/DC
0464 524 020
Spare parts list
Heliarc cooling unit
0463 369 001
Type
- 38 -
Notes
400 V
© ESAB AB 2013
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
0463 369 001
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© ESAB AB 2013
ACCESSORIES
TIG torches air cooled
0700 300 524
TXH 121, 4 m
0700 300 529
TXH 121, 8 m
0700 300 538
TXH 151, 4 m
0700 300 544
TXH 151, 8 m
0700 300 552
TXH 201, 4 m
0700 300 555
TXH 201, 8 m
TIG Torches water cooled
0700 300 561
TXH 251w, 4 m, OKC 50
0700 300 562
TXH 251 wF, 4 m, OKC 50
0700 300 563
TXH 251w, 8 m, OKC 50
0700 300 564
TXH 251wF, 8 m, OKC 50
0700 300 565
TXH 401w, 4 m
0700 300 566
TXH 401w HD, 4 m
0700 300 567
TXH 401w, 8 m
0700 300 568
TXH 401w HD, 8 m
TIG torches air cooled with built in remote control
0700 300 657
TXH 151, 8 m, wheel remote, 3.64 kg
0700 300 661
TXH 151, 8 m, flex wheel remote, 3.64 kg
0700 300 658
TXH 201, 8 m, wheel remote, 4.9 kg
0700 300 662
TXH 201, 8 m, flex wheel remote, 4.9 kg
TIG torches water cooled with remote control
0700 300 659
TXH 251w, 8 m, wheel remote, 2.8 kg
0700 300 660
TXH 401w, 8m, wheel remote, 4.56 kg
0700 300 663
TXH 251w, 8 m, flex wheel remote, 2.82 kg
0463 369 001
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© ESAB AB 2013
ACCESSORIES
0463 369 001
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© ESAB AB 2013
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
BULGARIA
ESAB Kft Representative Office
Sofia
Tel: +359 2 974 42 88
Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB International AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
www.esab.com
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
SOUTH AFRICA
ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
USA
ESAB Welding & Cutting
Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com