ESAB Caddy Professional 250 Bedienungsanleitung

Valid for serial no. 632--xxx--xxxx0457 552 301 GB 060814

Professional 250

Caddyt

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 DIRECTIVE 3........................................................

2SAFETY 3...........................................................

3 INTRODUCTION 5...................................................

4 TECHNICAL DATA 5.................................................

4.1 Equipment 5................................................................

4.2 Field of application 6.........................................................

5 INSTALLATION 6....................................................

5.1 Placing 6...................................................................

5.2 Connection 6...............................................................

6 OPERATION 7.......................................................

6.1 Overload protection 7........................................................

7 MAINTENANCE 7....................................................

7.1 Cleaning 7.................................................................

8 FAULT TRACING 8...................................................

9 ORDERING OF SPARE PARTS 8......................................

DIAGRAM 10............................................................

ORDERING NUMBER 11.................................................

SPARE PARTS LIST 12...................................................

ACCESSORIES 13.......................................................

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1DIRECTIVE

DECLARATION OF CONFORMITY

ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that weld-

ing power source Professional 250 from serial number 632 complies with standard IEC/EN 60974--1,

in accordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with

standard IEC/EN 60974--10 in accordance with the requirements of directive (89/336/EEC) and add-

endum (93/68/EEC).

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Kent Eimbrodt

Global Director Equipment and Automation

ESAB AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924

Laxå 2006--08--11

2SAFETY

Users of ESAB welding 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 welding equipment. The following recommen-

dations 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 welding

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 welding equipment must be familiar with:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding

2. The operator must ensure that:

Sno unauthorized person is stationed within the working area of the equipment when it is

started up.

Sno--one is unprotected when the arc is struck

3. The workplace must:

Sbe suitable for the purpose

Sbe free from drafts

4. Personal safety equipment

SAlways wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.

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

trapped or cause burns.

5. General precautions

SMake sure the return cable is connected securely.

SWork on high voltage equipment may only be carried out by a qualified electrician.

SAppropriate fire extinquishing equipment must be clearly marked and close at hand.

SLubrication and maintenance must not be carried out on the equipment during operation.

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WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-

TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE

BASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can kill

SInstall and earth the welding unit in accordance with applicable standards.

SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

SInsulate yourself from earth and the workpiece.

SEnsure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

SKeep your head out of the fumes.

SUse 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.

SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

SProtect bystanders with suitable screens or curtains.

FIRE HAZARD

SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearing

SProtect your ears. Use earmuffs or other hearing protection.

SWarn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

ESAB can provide you with all necessary welding protection and accessories.

This product is solely intended for arc welding.

WARNING!

Read and understand the instruction manual before installing

or operating.

Do not use the power source for thawing frozen pipes.

WARNING!

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic

Equipment and its implementation in accordance with national law, electrical equipment

that has reached the end of its life must be collected separately and returned to an

environmentally compatible recycling facility. As the owner of the equipment, you should

get information on approved collection systems from our local representative.

By applying this European Directive you will improve the environment and human health!

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3 INTRODUCTION

The Professional 250 are one transistor controlled welding power source designed

for welding with coated electrodes and for TIG welding (touch start).

The advanced electronics provide rapid control response, low power demand and

excellent welding characteristics. Inverter technology contributes to low weight and

compact dimensions of the units.

The rounded slimline shape of the unit makes it comfortable to carry. The strap can

be folded to serve as a carrying handle, or fully extended to serve as a shoulder

strap.

ESAB’s accessories for the product can be found on page 13.

4 TECHNICAL DATA

Performance:

at 35% duty cycle

at 60% duty cycle

at 100% duty cycle

250 A/30 V

180 A/27 V

140 A/26 V

Setting range continuously variable 4--250 A

Open circuit voltage 50--80 V

Mains supply:

voltage

frequency

fuse

mains cable, area

400 V AC

50/60 Hz

16 A*

4x1,5 mm2**

Enclosure class IP 23

Application class

Dimensions L x W x H 472x142x256

Weight 11 kg

*When welding below 100 A a 10 A slow fuse is adequate..

**Power cable ratings complies with Swedish regulations..

Duty cycle

The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-

tain load without overloading.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

Enclosure class

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

objects or water. Equipment marked IP23 is designed for indoor and outdoor use.

4.1 Equipment

Professional 250 is equipped with a remote control socket which activates

automatically when a remote control device is connected. NOTE! The contact pins L

and M must be strapped in the remote device’s connection cable for automatic

activationtofunction.Theinverterissuppliedwitha3meterlongmainscable.

Professional 250 is delivered with 5 meter long welding and return cables. These are

attached to cable connectors allowing quick change of polarity.

The manufacturer’s serial number is stamped on the rating plate.

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4.2 Field of application

Professional 250 supply direct current, which allows you to weld most alloyed and

non--alloyed steels, stainless steels and cast iron. .

With the Professional 250 you can use coated electrodes from ∅1.6 to ∅5mm

Tig--welding

TIG welding is particularly useful when high quality standards are required and when

welding thin sheet.

Before using the Caddy Professional 250 for TIG welding it must be equipped with:

Sa TIG torch and gas valve

Sa cylinder of argon

San argon regulator

Stungsten electrodes

Ssuitable filler metal, if necessary.

The best method to use is the touch start, where you gently stroke the tungsten

electrode against the workpiece to establish the arc.

5 INSTALLATION

The installation must be executed by a professional.

WARNING!

This product is intended for industrial use. In a domestic environment this product may cause radio

interference. It is the user’s responsibility to take adequate precautions.

5.1 Placing

Place the machine so that there is nothing to prevent the cooling air from passing

through it.

5.2 Connection

To get maximum performance from the Professional 250 it must be fitted with a 16A

slow fuse.

The Professional 250 have mains voltage compensation, which means that ¦10%

fluctuation in the supply voltage produces only ¦0.2% variation in the welding

voltage.

The Professional 250 is intended for 400V, 3 phase supplies. It can be used with 50

Hz or 60 Hz supplies.

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6OPERATION

General safety regulations for the handling of the equipment can be found on

page 3. Read through before you start using the equipment!

The power switch is at the rear of the Professional 250. The white

lamp on the front will glow when the power is on.

1. Yellow lamp

2. Welding current control 4--250 A

3. White lamp

4. Remote control socket

The current is adjusted using the knob on the front.

Important!

Only use the accompanying welding cable and return cable,

with a cross--sectional area of 35 mm@.(See list of spare parts

for order number).

6.1 Overload protection

To save you worrying about overloading the Caddy Professional 250 it has a thermal

cut--out that will trip before the temperature becomes too high. You can tell when the

rectifier has been overloaded because the yellow light comes on and it will no longer

be possible to weld.

7 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Note!

All guarantee undertakings from the supplier cease to apply if the customer himself

attempts any work in the product during the guarantee period in order to rectify any

faults.

Maintenance must be executed by a professional.

Only those persons who have appropriate electrical knowledge (authorized

personnel) may remove the safety plates.

7.1 Cleaning

Normally it is sufficient to blow the welding power source clean regularly using dry

compressed air (reduced pressure), and to clean the filter in the front regularly.

In dusty and dirty environment the welding power source should be cleaned at

shorter intervals.

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8 FAULT TRACING

Type of fault Measure

No arc is generated by

the welding power

source.

SMake sure the mains switch is on.

SCheck that the welding and return cables are properly connected.

SMake sure the welding current set is correct.

The welding current is

interrupted in the

course of welding.

SCheck if the thermal cut--out has tripped (the orange indicating lamp

on the front panel is on).

SCheck the mains fuse.

The thermal cut--out

trips frequently.

SCheck that the filter is not packed with dust.

SCheck that the ratings of the welding power source have not been

exceeded (overload of the power source).

Poor welding result. SCheck that the welding and return cables are properly connected.

SMake sure the welding current set is correct.

SCheck that there is nothing wrong with the electrodes.

9 ORDERING OF SPARE PARTS

Professional 250 is designed and tested in accordance with the international an Euro-

pean standards IEC/EN 60974--1 and EN 60974--10.

It is the obligation of the service unit which has carried out the service or repair work

to make sure that the product still conforms to the said standard.

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

this publication.

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Edition 060814

Diagram

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