ESAB Heliarc 161, Instruction Manual

Page 1: ...Heliarc 161 POWER SOURCE F15 655 E 12 2003 P N 0558002625 208 and 230 V 1 Phase 50 60 Hz INSTRUCTION MANUAL ...

Page 2: ...ill perform in conformity with the description thereof contained in this manual and accompanying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked periodically Mal functioning or poorly maintained equipment should not be used Parts that are broken missing worn distorted or contaminated should be replace...

Page 3: ...3 TABLE OF CONTENTS SECTION TITLE PAGE SECTION 1 GENERAL 11 SECTION 2 INSTALLATION 13 SECTION 3 OPERATION 17 SECTION 4 MAINTENANCE 21 SECTION 5 TROUBLESHOOTING 23 SECTION 6 REPLACEMENT PARTS 25 ...

Page 4: ...4 TABLE OF CONTENTS ...

Page 5: ...tances on the workpiece which might produce flammable or toxic vapors Do not do hot work on closed containers They may explode 4 Have fire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained in its use 5 Do not use equipment beyond its ratings For example overloaded welding cable can overheat and create a ...

Page 6: ...strike an arc on a cylinder 5 For additional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the installat...

Page 7: ...tintor de fuego para uso instantáneo como por ejemplo una manguera con agua cubeta con agua cubeta con arena o extintor portátil Asegúrese que usted esta entrenado para su uso 5 No use el equipo fuera de su rango de operación Por ejemplo el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego 6 Después de termirar la operación del equipo inspeccione el área de traba...

Page 8: ...capote de protección sobre la válvula si el regulador no está conectado Asegure y mueva los cilindros utilizando un carro o transporte adecuado Evite el manejo brusco de los Las siguientes publicaciones disponibles através de la American Welding Society 550 N W LeJuene Road Miami FL 33126 son recomendadas para usted 1 ANSI ASC Z49 1 Safety in Welding and Cutting 2 AWS C5 1 Recommended Practices fo...

Page 9: ...nt éloigné de la zone de travail augmente en effet le risque de passage d un courant de sortie par des chaînes de AVERTISSEMENT Ces règles de sécurité ont pour objet d assurer votre protection Veillez à lire et à observer les précautions énoncées ci dessous avant de monter l équipement ou de commercer à l utiliser Tout défaut d observation de ces précautions risque d entraîner des blessures graves...

Page 10: ...ières en matière de ventilation indiquées à l alinéa 6 de la norme Z49 1 de l AWS 5 ENTRETIEN DE L ÉQUIPEMENT Un équipement entretenu de façon défectueuse ou inadéquate risque non seulement de réaliser un travail de mauvaise qualité mais chose plus grave encore d entraîner des dommages corporels graves voire mortels en déclenchant des incendies ou des chocs électriques Observez par conséquent les ...

Page 11: ...A Hot Start Automatic built in Arc Force Automatic built in Ignition Electrode Scratch Ignition TIG HF Post Gas 0 20 sec Slope Down 0 10 sec Trigger Mode Momentary or Trigger Latch Weight 28 7 lbs 13 kg W x L x H 8 0in 200mm x 14 4in 360mm x 16 4in 410mm Options Accessories R 33 FM 580 Reg Flowmeter 21557 Primary Extension Cord 25 ft 50 amp 37833 FC 5B Foot Control 33646 Work Cable 15 ft TL 35881 ...

Page 12: ...ctrical power The Heliarc 161 should be placed within easy reach of the object to be welded F The machine components are maintained at proper operating temperatures by forced air which is drawn through the cabinet by the fan unit on the rear panel For this reason it is important that the machine be located in an open area where air can circulate freely at front and rear openings If space is at a p...

Page 13: ... hose to the bulk head fitting on rear of machine Connect the opposite end to the output fitting of the flowmeter regulator Set the flowmeter regulator to deliver between 15 to 25 cfh of Argon depending on application and surrounding conditions Primary Input Cable Gas Inlet Hose Connection Figure 1 Customer supplied single phase fused disconnect box and plug receptacle Figure 2 Rear panel connecti...

Page 14: ...elding Current Slope Down Time Post Gas Flow Time Polarity Selector Switch Start Current AC Balance Control Process Mode Selector Switch Negative Output Receptacle Gas Outlet to Torch Power Switch Positive Output Receptacle Remote Control Socket 14 pin Over Temp ...

Page 15: ...h initiates the weld stop pro cedure If the switch is repressed and then im mediately released the arc will go off immedi ately Alternatively repressing and holding the switch permits the current to slope down to its final level where it will remain until the switch is finally released C 2 Stroke Touch Start Non HF When HF may cause problems in surrounding sensitive equip ment see HF Emission Prev...

Page 16: ...p to 20 seconds 2 15 Over Temperature Light In the event the unit exceeds its duty cycle and internal component temperatures get too high an internal tem perature sensor will switch off welding output and the over temperature light will illuminate In this event leave the unit switched on with the fans running Reset is auto matic after the unit has cooled ...

Page 17: ...en AC TIG welding turning the balance control clockwise to give greater cleaning increases the heat in the tungsten and hence reduces its maxi mum current capacity More melting or rounding or the tungsten will also be seen 3 2 TIG Welding 1 Set the front panel controls as required 2 or 4 stroke HF or touch start TIG mode 4 Stroke inoperative if Foot Control is used AC or DC process AC balance if A...

Page 18: ...G GTAW Welding Connection Diagram Figure 7 STICK SMAW Welding Connection Diagram NOTE THE FOOT CONTROLLED MUST BE REMOVED FOR STICK OPERATION IMPORTANT Connect the TIG Torch to the Negative Output Terminal Set the Start Current Control 5 Set the AC Balance to 3 IMPORTANT Connected the Electrode Holder to the Positive Output Terminal Set the Start Current Control 100 ...

Page 19: ... selected press the torch foot switch and lightly touch the tungsten tip to the work and lift it off again to initiate the arc 9 In the 4 stroke mode the torch switch can be released once the arc has struck Note In 4 stroke the arc will start at the start current setting until the switch is released 10 Release press release the torch switch to down slope the current and stop welding 11 Maintain th...

Page 20: ...ol of molten metal keeping the electrode at approximately 65 80 to the workpiece If the electrode freezes ie sticks to the workpiece gently twist the electrode and pull it free If this is not possible release the electrode from the holder switch off the supply and cut the electrode free Freezing will occur if heavy contact is made with the workpiece at too low a current setting 6 Once the arc is s...

Page 21: ...articu larly dirty or dusty environments While the unit is open check that internal wiring and all connectors are in good condition It is recommended that external connections and cables primary gas welding should be regularly inspected for signs of deterioration or damage Check that the front panel twist lock power connection plugs are properly locked in place push in and twist and show no eviden...

Page 22: ...22 SECTION 4 MAINTENANCE ...

Page 23: ...dequate Check work lead is properly connected to a clean location on the workpiece Check the torch switch is properly connected at the 14 pin socket Check the switch and switch wires Check a 2 thoriated ceriated or lanthanated tungsten is being used Check for a good work lead connection Test machine in touch start mode to confirm arc can be established Regrind tung sten tip Check TIG torch is conn...

Page 24: ...OID VALVE 230V 0558002748 CN1 REMOTE CONTROL TORCH CONNECTOR WITH L1 L2 0558002749 L1 L2 COMMON MODE INDUCTORS 3 TURNS REF VR1 VR2 FAN 120X120 220 230V 50 60Hz 0558002738 INVSS2 v 7 INVERTER PCB 0558002740 SSACDC CONTROL PCB 0558002741 SSHFAC1 HIGH FREQUENCY GENERATOR PCB 0558002743 SSACINV WELDING SIDE INVERTER PCB 0558002742 ...

Page 25: ...ich the parts will be used The serial number is stamped on the unit nameplate 6 2 Ordering Replacement parts may be ordered from your ESAB distributor or from ESAB Welding Cutting Products Attn Customer Service Dept PO Box 100545 Ebenezer Road Florence SC 29501 0545 Be sure to indicate any special shipping instruc tions when ordering replacement parts Refer to the Communications Guide on back cove...

Page 26: ...26 SECTION 6 REPLACEMENT PARTS 12 9 3 4 15 5 17 18 16 8 14 13 6 7 11 10 19 20 ...

Page 27: ...ter Main PCB INVSS 9 0558002741 Control PCB SSACDC 10 0558002742 Inverter AC Ass y Fan Module SSACINV 11 0558002743 HF PCB SSHFAC 12 0558002744 HF Generator T1 13 34574 Main Power Cable w Plug 10Ft 14 0558002746 EMI Filter 15 0558002747 ON OFF Switch S1 16 0558002748 Solenoid Valve Assembly EV1 17 0558002749 Torch Socket Torch 18 58V58 Bulkhead Adaptor for Gas Fittings 19 136Z08 Gas Fitting 20 35N...

Page 28: ...28 SECTION 6 REPLACEMENT PARTS ...

Page 29: ...29 Notes ...

Page 30: ...30 Notes ...

Page 31: ... Control Socket in more detail The B Edition of this book updates the Controls and Connections labels on page 10 Revision C update details were not added to this listing when completed Revision D Replaced schematic with latest version and made various text changes throughout the manual Revision E Updated block diagram on Page 24 ...

Page 32: ...ranty Returns Authorized Repair Stations Welding Equipment Troubleshooting C TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Hours 8 00 AM to 5 00 PM EST Part Numbers Technical Applications Specifications Equipment Recommendations D LITERATURE REQUESTS Telephone 843 664 5562 Fax 843 664 5548 Hours 7 30 AM to 4 00 PM EST E WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664 5557 ...