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ESAB ES 95i

OPERATION 4-10 Manual 0-5458

Art # A-07711_AB

4

3

2

1

Figure 4-26: Step back sequence

Art # A-07712

Figure 4-27: Chain intermittent welding

Art # A-07713_AB

Figure 4-28: Staggered intermittent welding

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Summary of Contents for ES 95i

Page 1: ...A 13026 95 3163339 R vision AA Issue Date June 8 2016 Manual No 0 5458 Operating Manual ESAB ES 95i Inverter Arc Welder esab com...

Page 2: ...take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand...

Page 3: ...of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused...

Page 4: ...reof contained in this manual and accom panying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked period...

Page 5: ...X 01 603 298 7402 The following harmonised standard in force within the EEA has been used in the design EN 60974 1 2012 Arc Welding Equipment Part 1 Welding power sources EN 60974 10 2007 Arc Welding...

Page 6: ......

Page 7: ...OPERATION 4 1 4 01 Front Panel 4 1 4 02 SMAW Electrode Polarity 4 2 4 03 Effects of SMAW Stick Welding Various Materials 4 2 4 04 GTAW Lift TIG Electrode Polarity 4 3 4 05 Guide for Selecting Filler...

Page 8: ...ction 5 1 5 02 SMAW Stick Welding Problems 5 2 5 03 GTAW Lift TIG Welding Problems 5 3 5 04 Power Source Problems 5 4 APPENDIX 1 REPLACEMENT PARTS A 1 APPENDIX 2 OPTIONS AND ACCESSORIES A 2 APPENDIX 3...

Page 9: ...d up no one is unprotected when the arc is struck 3 The workplace must be suitable for the purpose be free from drafts 4 Personal safety equipment Always wear recommended personal safety equipment suc...

Page 10: ...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 mate rials nearby NOI...

Page 11: ...Acrobat PDF format by going to the ESAB web site listed below http www esab com 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usua...

Page 12: ...porting 2 06 Duty Cycle The rated duty cycle of a Welding Power Source is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the...

Page 13: ...not exposed to direct sunlight or rain Place at a distance of 12 300mm or more from walls or similar that could restrict natural air flow for cooling WARNING ESAB advises that this equipment be elec t...

Page 14: ...ource Based on Article 630 National Electrical Code An individual branch circuit capable of carrying 20 amperes and time delay fuses or circuit breaker protec tion is recommended for this application...

Page 15: ...urn on after the input capacitors have charged to operating voltage after approximately 5 seconds NOTE Damage to the PCA could occur if 133 VAC or higher is applied to the Primary Power Cable Table 3...

Page 16: ...ties are to be carried out 8 The immunity of other equipment in the environment the user shall ensure that other equipment being used in the environment is compatible this may require additional prote...

Page 17: ...ng to national regulations 6 Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening the entire...

Page 18: ...rkpiece 4 Plug the power cable into the appropriate outlet and turn the switch to the ON position The power L E D light should illuminate 5 Set the Process Selection Switch to SMAW Stick 6 Set the wel...

Page 19: ...g a secured Argon cylinder slowly crack open then close the cylinder valve while standing off to the side of the valve This will remove any debris that may be around the valve regulator seat area 4 In...

Page 20: ...grinding wheel is turning 12 Install the tungsten with approximately 1 8 to sticking out from the gas cup ensuring you have correct sized collet 13 Tighten the back cap 14 You are now ready to begin T...

Page 21: ...tween GTAW Lift TIG and SMAW Stick Welding modes B Power On Indicator The Power ON Indicator illuminates when the ON OFF switch is in the ON position and the nominal mains voltage is present C Over He...

Page 22: ...e weld area and if suitable precautions are not taken the occurrence in this zone of under bead cracks Hardened zone and under bead cracks in the weld area may be reduced by using the correct electrod...

Page 23: ...mm 13 CFH 6 LPM Butt Corner 50 60 35 50 Lap Filler 1 16 1 6mm 60 70 40 60 1 16 1 6mm 1 16 1 6mm 15 CFH 7 LPM Butt Corner 70 90 50 70 Lap Filler 1 8 3 2mm 80 100 65 85 1 16 1 16mm 3 32 2 4mm 15CFH 7 LP...

Page 24: ...t horizontal vertical and overhead positions Numerous applications call for welds to be made in positions intermediate between these Some of the common types of welds are shown in Figures 4 2 through...

Page 25: ...Not less than 70 Single Vee Butt Joint Not less than 45 1 6mm 1 16 max Art A 07695_AE 4 12 Joint Preparations In many cases it will be possible to weld steel sections without any special preparation F...

Page 26: ...practice will soon remedy both of these faults Art A 07696_AB 20 1 6 mm 1 16 Figure 4 11 Striking an arc 4 16 Arc Length The securing of an arc length necessary to produce a neat weld soon becomes al...

Page 27: ...dicular to the line of the fillet and about 45 from the vertical Some electrodes require to be sloped about 20 away from the perpendicular position to prevent slag from running ahead of the weld Refer...

Page 28: ...y occur The study of distortion is so complex that only a brief outline can be attempted hear 4 20 The Cause of Distortion Distortion is cause by A Contraction of Weld Metal Molten steel shrinks appro...

Page 29: ...ct of peening is relatively shallow and is not advisable on the last layer B Distribution of Stresses Distortion may be reduced by selecting a welding sequence which will distribute the stresses suita...

Page 30: ...AB ES 95i OPERATION 4 10 Manual 0 5458 Art A 07711_AB 4 3 2 1 Figure 4 26 Step back sequence Art A 07712 Figure 4 27 Chain intermittent welding Art A 07713_AB Figure 4 28 Staggered intermittent weldin...

Page 31: ...solvents that are recommended for cleaning electrical apparatus CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sen...

Page 32: ...ger electrodes and preheat the plate B Increase welding current C Adjust angle so the welding arc is directed more into the base metal D Reduce travel speed of electrode E Clean surface before welding...

Page 33: ...by grinding contaminates off B Check gas lines for cuts and loose fitting or change gas cylinder 8 Poor weld finish Inadequate shielding gas Increase gas flow or check gas line for problems 9 Arc flut...

Page 34: ...extinguish before resuming welding 3 Maximum output welding current cannot be achieved with nominal Mains supply voltage Defective control circuit Have an Accredited Thermal Arc Service Provider inspe...

Page 35: ...sor 95i CSA W7003077 Thermistor 95i W7003016 Terminal Output 95i W7003019 Handle 95i CSA W7003078 Knob Control Red 20 OD x 6 ID W7003079 Panel Base 95i CSA W7003080 Panel Cover 95i W7003043 Panel Fron...

Page 36: ...se Connection 600300 Power Adapter 115V 20A Socket to 15A Plug W4013300 USA Graphics Auto Darkening welding helmet spare cover lens and operating manual W4011700 Canadian Graphics Auto Darkening weldi...

Page 37: ...PENDIX APPENDIX 3 SYSTEM SCHEMATIC AC 1 AC 3 2 4 24V L TRANS2 OC Pr2 OC1 OC2 Pr1 DR1 DR2 DR5 DR6 DR3 DR4 DR7 DR8 DR1 DR2 DR3 DR4 DR5 DR8 DR6 DR7 OC1 OC2 K1 AC115V 60HZ OUT OUT FAN LED1 LED2 VR1 PTC IG...

Page 38: ...ESAB ES 95i APPENDIX A 4 Manual 0 5458 This Page Intentionally Blank...

Page 39: ......

Page 40: ...x 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...

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