heliarc 283i ac/dc, 353i ac/dc, heliarc cooling...

Instruction manual

0463 369 001 GB 20160105 Valid for: 283i = S2733450468 353i = S2733450508Cooling unit = S2733450427

Heliarc 283i AC/DCHeliarc 353i AC/DCHeliarc cooling unit

TABLE OF CONTENTS

0463 369 001 © ESAB AB 2016

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

2 INTRODUCTION ...................................................................................................72.1 Overview ...............................................................................................................7

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

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

4 INSTALLATION...................................................................................................104.1 General ................................................................................................................10

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

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

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

5 OPERATION .......................................................................................................135.1 Overview .............................................................................................................13

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

5.3 Quick set up........................................................................................................165.3.1 Operation mode selection ................................................................................165.3.2 Stick (SMAW) mode.........................................................................................165.3.3 TIG (GTAW) two stroke mode with remote switch ...........................................175.3.4 TIG (GTAW) two stroke mode with foot control................................................175.3.5 TIG (GTAW) four stroke mode .........................................................................175.3.6 TIG (GTAW) spot mode....................................................................................185.3.7 AC mode ..........................................................................................................185.3.8 Pulse mode - Peak/Background.......................................................................195.3.9 Pulse mode - Frequency/Duty cycle ................................................................195.3.10 Store and recall programs................................................................................205.3.11 General functions .............................................................................................215.3.12 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 ..................................................................................................286.1 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

TABLE OF CONTENTS

0463 369 001 © ESAB AB 2016

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

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

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

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

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

Rights reserved to alter specifications without notice.

1 SAFETY

0463 369 001 - 5 - © ESAB AB 2016

1 SAFETYUsers of ESAB equipment have the ultimate responsibility for ensuring that anyone whoworks on or near the equipment observes all the relevant safety precautions. Safetyprecautions must meet the requirements that apply to this type of equipment. The followingrecommendations should be observed in addition to the standard regulations that apply tothe workplace.

All work must be carried out by trained personnel well-acquainted with the operation of theequipment. Incorrect operation of the equipment may lead to hazardous situations which canresult 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

1 SAFETY

0463 369 001 - 6 - © ESAB AB 2016

WARNING!Arc welding and cutting can be injurious to yourself and others. Take precautionswhen welding and cutting. Ask for your employer's safety practices which shouldbe 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 andwear protective clothing

• Protect bystanders with suitable screens or curtains

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure therefore that there are noinflammable 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 beforeinstalling or operating.

CAUTION!Class A equipment is not intended for use in residentiallocations where the electrical power is provided by thepublic low-voltage supply system. There may be potentialdifficulties in ensuring electromagnetic compatibility ofclass A equipment in those locations, due to conductedas well as radiated disturbances.

2 INTRODUCTION

0463 369 001 - 7 - © ESAB AB 2016

2 INTRODUCTION

2.1 OverviewThe Heliarc 283i and 353i AC/DC are welding power sources intended for MMA and TIGwelding. 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 theHeliarc cooling unit.

The Heliarc cooling unit is used with the Heliarc 283i and 353i AC/DC. It distributes 2litres/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 ofthis manual.

2.2 EquipmentThe power sources comes with:

• return cable with clamp• mains cable• gas hose• instruction manual

The cooling unit comes with:

• instruction manual

3 TECHNICAL DATA

0463 369 001 - 8 - © ESAB AB 2016

3 TECHNICAL DATA283i 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 mmLine fuse min 25 A min 25 ASetting range GTAW/TIG AC/DC 4 - 280 A 4 - 350 AMaximum outputGTAW/TIG, AC/DC 280 A at 100% 350 A at 45%Gas pre-flow 0.5 - 30 sec 0.5 - 30 secSlope up/slope down 0.1 - 10 sec 0.1 - 10 secGas post-flow 0.5 - 30 sec 0.5 - 30 secFrequency AC 20 -200 Hz 20 - 200 HzAC balance 10 - 90% 10 - 90%DC Pulse mode frequency 0.4 - 300 Hz 0.4 - 300 HzAC Pulse mode frequency 0.4 - 2 Hz 0.4 - 2 HzPulse duty (pulsetime/background time) 30 - 65% 30 - 65%Background current 10 - 90 A 10 - 90 ASlope down time 0.1 -10 s 0.1 - 10 sStart/crater current (4-stroke) 10 - 90 % 10 - 90 %Post purge time 0.5 - 30 s 0.5 - 30 sRemote start point current 4 - 100 A 4 - 100 AOpen circuit voltage max 68 V 68 VPower factor at 100 % TIG mode 0.75 0.8Setting range SMAW/MMA 4 - 280 A 4 - 350 AMaximum output SMAW/MMA, AC/DC20% duty cycle - 350 A40% duty cycle 280 A -KVA GTAW/TIG 11 14.5KVA SMAW/MMA 14.2 19Enclosure class IP 21S IP 21SDimensions l × w × h 600 × 300 × 620 mm 600 × 300 × 620 mmWeight without cooling unit 50 kg 50 kgWeight trolley 35 kg 35 kg

Enclosure classThe IP code indicates the enclosure class, i. e. the degree of protection against penetrationby solid objects or water.

Equipment marked IP21 is intended for indoor use.

3 TECHNICAL DATA

0463 369 001 - 9 - © ESAB AB 2016

Heliarc cooling unitMains voltage 400 V ±10%, 1~, 50/60 HzMaximum power supply current 0.75 AP1l/min 0.5 kW

Cooling power 60 WCoolant "ESAB's ready mixed coolant, see the

"ACCESSORIES" chapter.Coolant quantity 5 l (delivered with approx. 2.5 l)Pressure max 0.35 MPaMaximum water flow 2.0 l/minOperating temperature -10° to +40°CTransportation temperature -20° to +55°CDimensions (l × w × h) 475 × 310 × 250 mmWeight empty 14 kgEnclosure class IP21

Enclosure classThe IP code indicates the enclosure class, i. e. the degree of protection against penetrationby solid objects or water.

Equipment marked IP21 is intended for indoor use.

4 INSTALLATION

0463 369 001 - 10 - © ESAB AB 2016

4 INSTALLATION

4.1 GeneralThe installation must be carried out by a professional.

4.2 Lifting instructionsLifting the power source by hand.

WARNING!The power source weighs 50 kg (110 lbs).

WARNING!Be two persons and lift the powersource by using the two handles.

Lifting the power source using hoist and strap.

WARNING!Lift the power source by using theeyebolt. Keep the power supplyas horizontal as possible.

WARNING!Secure the equipment -particularly if the ground isuneven or sloping.

4.3 LocationPosition the welding power source such that its cooling air inlets and outlets are notobstructed. 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.

4 INSTALLATION

0463 369 001 - 11 - © ESAB AB 2016

4.4 Mains supplyNOTE!Mains supply requirements

This equipment complies with IEC 61000-3-12 provided that the short-circuitpower is greater than or equal to Sscmin at the interface point between the user'ssupply and the public system. It is the responsibility of the installer or user of theequipment to ensure, by consultation with the distribution network operator ifnecessary, that the equipment is connected only to a supply with a short-circuitpower greater than or equal to Sscmin. Refer to the technical data in theTECHNICAL DATA chapter.

CAUTION!Make sure that the ON/OFF switch is set to OFF (0) before making any electricalconnections between the power source and the mains power supply.

Make sure that the welding power source is connected to the correct supply voltage and thatit is protected by the correct fuse rating. The mains distribution panel must comply with theregulations in force in the country of use. The mains supply system must be of the industrialtype.

A protective earth connection must be made in accordance with regulations. The powersource must be correctly connected to earth to protect the operator. It is indispensable toprovide good earthing by means of the yellow-green lead in the power cable, to preventdischarges 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 withthe 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 Vrated, minimum voltage 320 V, maximum voltage 480 V).

Heliarc 283i AC/DC Heliarc 353i AC/DCMains voltage 400 V, 3~ , 50/60 Hz 400 V, 3~ , 50/60 HzFuse 20 A 25 A

Connection instruction cooling unitMake sure that the Heliarc is correctly connected to earth to protect the operator. It isindispensable to provide good earthing by means of the yellow-green lead in the powercable, to prevent discharges due to accidental contacts with earthed objects.

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

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

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

4 INSTALLATION

0463 369 001 - 12 - © ESAB AB 2016

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. Tostart the cooling unit it is necessary to switch on both the power source and the cooling unit.

Hydraulic connectionConnect 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.

5 OPERATION

0463 369 001 - 13 - © ESAB AB 2016

5 OPERATION

5.1 OverviewGeneral 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 sourceFront connections

Type Connection PIN Description

TIG

YES A GasTIG TORCH B NegativeYES D-F PinEARTH CLAMP E Positive

Type Connection PIN Description

MMA

NO A GasEARTH CLAMP B NegativePOSSIBLE REMOTE F PinELECTRODE E Positive

NOTE!Connection D, 2 pin cannon, can be used for either analogue foot control ortorch.

5 OPERATION

0463 369 001 - 14 - © ESAB AB 2016

Cooling unit connection

4 Pinconnector

PIN Description

Power supply1 Power supply common2 Power supply 115/230 V AC3 Power supply 400 V AC

GRD 4 Chassis common

14 pin connector

14 Pinconnector

PIN Description

Torch triggerA Torch switchB Torch switch

Remote control

E Remote control circuit commonF +5 V DC input remote controlG +5 V DC output remote controlD +5 V DC output remote control

GRD H Chassis common

2 pin connector

2 Pinconnector

PIN Description

Torch trigger

A Torch switchB Torch switch

5 OPERATION

0463 369 001 - 15 - © ESAB AB 2016

Front panel

Item Denomination1 Power source live LED2 Welding enabled LED3 Over temperature LED4 Volt display5 Ampere display6 AC mode button7 AC mode LED8 AC frequency setting, 20-200 Hz9 AC balance setting, 10-90%10 Pulse mode button (0.4-300 Hz DC, 0.4-2 Hz AC)11 Pulse mode LED12 Pre-gas (0.1-2.5 sec) Post-gas (0.1-30 sec) button13 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 settings16 HF LED17 HF button18 Select mode button19 Remote control button20 Remote button LED21 Mode TIG dual schedule LED22 Mode TIG spot LED23 Mode TIG 4 stroke LED

5 OPERATION

0463 369 001 - 16 - © ESAB AB 2016

Item Denomination24 Mode TIG 2 stroke LED25 Mode Stick LED

5.3 Quick set up5.3.1 Operation mode selection

Press the select mode button (1) repeatedly until the desired mode is selected, indicated bya 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 islit.

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).

5 OPERATION

0463 369 001 - 17 - © ESAB AB 2016

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

5 OPERATION

0463 369 001 - 18 - © ESAB AB 2016

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 inV 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.

5 OPERATION

0463 369 001 - 19 - © ESAB AB 2016

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 theencoder 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.

5 OPERATION

0463 369 001 - 20 - © ESAB AB 2016

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 programs60 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.

5 OPERATION

0463 369 001 - 21 - © ESAB AB 2016

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 10seconds) 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 sourceHot start TIG AC

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

5 OPERATION

0463 369 001 - 22 - © ESAB AB 2016

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 sourceTIG 2-stroke

AmpereA = Pre gasB = Arc ONC = t slopeD = Arc OFFE = Post gas timeF = Torch trigger ONG = Torch trigger OFF

t

TIG 4-stroke

AmpereA = Pre gasB = Arc ONC1 = t slope upC2 = t slope down

D = Arc offE = Post gas timeF = Torch trigger ONG = Torch trigger OFFH = Torch trigger ON/OFF

t

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

5 OPERATION

0463 369 001 - 23 - © ESAB AB 2016

AmpereA = Pre gasB = Arc ONC1 = t slope upC2 = t slope down

D = Arc OFFE = Post gas timeF = Torch trigger ONG = Torch trigger OFFH = Torch trigger ON/OFFI = Torch trigger ONJ = Torch trigger OFF

t

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

IOUT (A)

It is also possible to adjust the AC balance from 10% to 90% EN (Electrode Negative) withthe 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.

5 OPERATION

0463 369 001 - 24 - © ESAB AB 2016

5.6 TIG welding informationElectrode typeFor 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 theelectrode as shown in the figure below.

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

Angle (°) Welding current30 5-3060 - 90 30 - 12090 - 120 120 - 160

Filler materialMany 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 asthe material to be welded.

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

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

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

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

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

5 OPERATION

0463 369 001 - 25 - © ESAB AB 2016

5.7 Power source overheatedDuty cycleThe duty cycle refers to the time as a percentage of a ten-minute period that you can weld orcut 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 unitFront panel

1 Main switch2 Optical alarm LED3 Cooling unit ON/OFF4 Cold water outlet, blue tube on the torch5 Fuse6 Sound alarm for lack of water circulation7 Hot water return, red tube on the torch

ILME 4-way connector

4 Pinconnector

PIN Description

Power supply1 Power supply common2 Power supply 115/230 V AC3 Power supply 400 V AC

GRD 4 Chassis common

5 OPERATION

0463 369 001 - 26 - © ESAB AB 2016

5.9 Starting up the cooling unitNOTE!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 liquidlevel is to low.

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

5 OPERATION

0463 369 001 - 27 - © ESAB AB 2016

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.

6 MAINTENANCE

0463 369 001 - 28 - © ESAB AB 2016

6 MAINTENANCE

6.1 OverviewRegular maintenance is important for safe, reliable operation.

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

CAUTION!All warranty undertakings from the supplier cease to apply if the customerattempts any work to rectify any faults in the product during the warranty period.

6.2 Power sourceCheck regularly that the welding power source is not clogged with dirt. Clogged or blockedair 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 (reducedpressure) once a year.

6.3 Welding torchA regular programme of care and maintenance reduces unnecessary and expensivedowntime.

Each time a wire bobbin is changed, the welding torch should be removed from the powersource 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 unitFor the cooling unit it is sufficient to keep the inside clean. A dusty environment requires amore frequent cleaning.

WARNING!Before any actions are taken, disconnet the cooling unit from the mains powersupply (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.

6 MAINTENANCE

0463 369 001 - 29 - © ESAB AB 2016

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 coolantTo 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).

7 FAULT TRACING

0463 369 001 - 30 - © ESAB AB 2016

7 FAULT TRACINGTry these recommended checks and inspections before sending for an authorized servicetechnician.

Fault tracing power source

Type of fault Corrective actionNo 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 duringwelding.

• Check whether the overloading protectionhas 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. thatthe unit is not being overloaded).

Poor welding performance. • Check that the welding and return cablesare correctly connected.

• Check that the correct current value isset.

• Check that the correct wire or electrode isused.

• Check the mains power supply fuses.• Check the gas pressure in the equipment

connected to the power source."TRI - ALA" (Trigger Alarm) on display whenpower source is turned on.

NOTE!This error occurs if the torchtrigger is pushed when the powersource is started.

• 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.

7 FAULT TRACING

0463 369 001 - 31 - © ESAB AB 2016

Fault tracing cooling unit

Type of fault Corrective actionDoes 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 areno 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 upwith coolant and make sure that there areno leaks.

8 ORDERING SPARE PARTS

0463 369 001 - 32 - © ESAB AB 2016

8 ORDERING SPARE PARTSRepair 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 withinternational and european standards IEC/EN 60974-1 and IEC/EN 60974-10. Oncompletion of service or repair work, it is the responsibility of the person(s) performing thework 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 andeuropean standard IEC/EN 60974-2. On completion of service or repair work, it is theresponsibility of the person(s) performing the work to ensure that the product still complieswith the requirements of the above standard.

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

ORDERING NUMBERS

0463 369 001 - 37 - © ESAB AB 2016

ORDERING NUMBERS

Ordering number Denomination Type Notes0700 300 701 Welding power source Heliarc 283i AC/DC 400 V0700 300 702 Welding power source Heliarc 353i AC/DC 400 V0700 300 703 Cooling unit Heliarc cooling unit0464 524 010 Spare parts list Heliarc 283i AC/DC,

353i AC/DC400 V

0464 524 020 Spare parts list Heliarc cooling unit

ACCESSORIES

0463 369 001 - 38 - © ESAB AB 2016

ACCESSORIES0558 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

ACCESSORIES

0463 369 001 - 39 - © ESAB AB 2016

TIG torches air cooled0700 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 mTIG Torches water cooled0700 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 mTIG torches air cooled with built in remote control0700 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 control0700 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

ESAB subsidiaries and representative offices

www.esab.com

EuropeAUSTRIAESAB Ges.m.b.HVienna-LiesingTel: +43 1 888 25 11Fax: +43 1 888 25 11 85

BELGIUMS.A. ESAB N.V.Heist-op-den-BergTel: +32 15 25 79 30Fax: +32 15 25 79 44

BULGARIAESAB Kft Representative OfficeSofiaTel: +359 2 974 42 88Fax: +359 2 974 42 88

THE CZECH REPUBLICESAB VAMBERK s.r.o.VamberkTel: +420 2 819 40 885Fax: +420 2 819 40 120

DENMARKAktieselskabet ESABHerlevTel: +45 36 30 01 11Fax: +45 36 30 40 03

FINLANDESAB OyHelsinkiTel: +358 9 547 761Fax: +358 9 547 77 71

GREAT BRITAINESAB Group (UK) LtdWaltham CrossTel: +44 1992 76 85 15Fax: +44 1992 71 58 03

ESAB Automation LtdAndoverTel: +44 1264 33 22 33Fax: +44 1264 33 20 74

FRANCEESAB France S.A.Cergy PontoiseTel: +33 1 30 75 55 00Fax: +33 1 30 75 55 24

GERMANYESAB GmbHSolingenTel: +49 212 298 0Fax: +49 212 298 218

HUNGARYESAB KftBudapestTel: +36 1 20 44 182Fax: +36 1 20 44 186

ITALYESAB Saldatura S.p.A.Bareggio (Mi)Tel: +39 02 97 96 8.1Fax: +39 02 97 96 87 01

THE NETHERLANDSESAB Nederland B.V.AmersfoortTel: +31 33 422 35 55Fax: +31 33 422 35 44

NORWAYAS ESABLarvikTel: +47 33 12 10 00Fax: +47 33 11 52 03

POLANDESAB Sp.zo.o.KatowiceTel: +48 32 351 11 00Fax: +48 32 351 11 20

PORTUGALESAB LdaLisbonTel: +351 8 310 960Fax: +351 1 859 1277

ROMANIAESAB Romania Trading SRLBucharestTel: +40 316 900 600Fax: +40 316 900 601

RUSSIALLC ESABMoscowTel: +7 (495) 663 20 08Fax: +7 (495) 663 20 09

SLOVAKIAESAB Slovakia s.r.o.BratislavaTel: +421 7 44 88 24 26Fax: +421 7 44 88 87 41

SPAINESAB Ibérica S.A.Alcalá de Henares (MADRID)Tel: +34 91 878 3600Fax: +34 91 802 3461

SWEDENESAB Sverige ABGothenburgTel: +46 31 50 95 00Fax: +46 31 50 92 22

ESAB International ABGothenburgTel: +46 31 50 90 00Fax: +46 31 50 93 60

SWITZERLANDESAB AGDietikonTel: +41 1 741 25 25Fax: +41 1 740 30 55

UKRAINEESAB Ukraine LLCKievTel: +38 (044) 501 23 24Fax: +38 (044) 575 21 88

North and South AmericaARGENTINACONARCOBuenos AiresTel: +54 11 4 753 4039Fax: +54 11 4 753 6313

BRAZILESAB S.A.Contagem-MGTel: +55 31 2191 4333Fax: +55 31 2191 4440

CANADAESAB Group Canada Inc.Missisauga, OntarioTel: +1 905 670 02 20Fax: +1 905 670 48 79

MEXICOESAB Mexico S.A.MonterreyTel: +52 8 350 5959Fax: +52 8 350 7554

USAESAB Welding & CuttingProductsFlorence, SCTel: +1 843 669 44 11Fax: +1 843 664 57 48

Asia/PacificAUSTRALIAESAB South PacificArcherfield BC QLD 4108Tel: +61 1300 372 228Fax: +61 7 3711 2328

CHINAShanghai ESAB A/PShanghaiTel: +86 21 2326 3000Fax: +86 21 6566 6622

INDIAESAB India LtdCalcuttaTel: +91 33 478 45 17Fax: +91 33 468 18 80

INDONESIAP.T. ESABindo PratamaJakartaTel: +62 21 460 0188Fax: +62 21 461 2929

JAPANESAB JapanTokyoTel: +81 45 670 7073Fax: +81 45 670 7001

MALAYSIAESAB (Malaysia) Snd BhdUSJTel: +603 8023 7835Fax: +603 8023 0225

SINGAPOREESAB Asia/Pacific Pte LtdSingaporeTel: +65 6861 43 22Fax: +65 6861 31 95

SOUTH KOREAESAB SeAH CorporationKyungnamTel: +82 55 269 8170Fax: +82 55 289 8864

UNITED ARAB EMIRATESESAB Middle East FZEDubaiTel: +971 4 887 21 11Fax: +971 4 887 22 63

AfricaEGYPTESAB EgyptDokki-CairoTel: +20 2 390 96 69Fax: +20 2 393 32 13

SOUTH AFRICAESAB Africa Welding & CuttingLtdDurbanvill 7570 - Cape TownTel: +27 (0)21 975 8924

DistributorsFor addresses and phonenumbers to our distributors inother countries, please visit ourhome page

www.esab.com

heliarc 283i ac/dc, 353i ac/dc, heliarc cooling...

Documents