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ET 201i DC

  

INTRODUCTION 

0-5452

2-2

2.06  Duty Cycle

The rated duty cycle of a Welding Power Source, is the percentage of a ten minute time period that it may be operated 

at its rated output current without exceeding the temperature limits of the insulation of the component parts. To explain 

the 10 minute duty cycle period, suppose a Welding Power Source is designed to operate with a 30% duty cycle at 

160 amperes and 26.4 volts. This means that it has been designed and built to provide the rated amperage (160A) for 

3 minutes, i.e. arc welding time, out of every 10 minute period (30% of 10 minutes is 3 minutes). During the other 7 

minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool.

2.07 Specifications

Power Source Part Number 

W1003806

Mains Power

Nominal Supply Voltage

AC 115V 

AC 208/230V 

Number of Phases

Single Phase

Single Phase

Input Voltage Range

AC 104- 127V 

AC 187- 253V 

Nominal Supply Frequency

50/60 Hz

50/60 Hz

Effective Input Current (l1eff) for STICK (SMAW) Welding

18.3 Amps

15.8/14.2 Amps

Effective Input Current (l1eff) for LIFT TIG/HF TIG (GTAW) 

Welding

16.4 Amps

12.3/11.1 Amps

Maximum Input Current (l1 max) for STICK (SMAW) Welding

∆ 27.2 Amps

∆ 35.2/31.6 Amps

Maximum Input Current (l1 max) for LIFT TIG/HF TIG (GTAW) 

Welding

∆ 23.2 Amps

∆ 24.6/22.1 Amps

Single Phase Generator Requirements [Continuous rating 

at nominal supply voltage with maximum output for STICK 

(SMAW) welding]

4 KVA

7.3 KVA

Welding Output

Welding Current Range

Stick: 10 - 125 Amps 

TIG: 10 - 160 Amps

Stick/TIG:  

10 - 200 Amps

Nominal DC Open Circuit Voltage (OCV)

71V

71V

Welding Output, 104º F (40º C), 10 min. 

 (Quoted figures refer to STICK (SMAW) output)

100A  @ 45%, 24.0V 

87A @ 60%, 23.5V 

68A @ 100%, 22.7V

200A  @ 20%, 28V 

116A @ 60%, 24.6V  

90A @ 100%, 23.6V

Rated Input Current (A) 

                                             For STICK (SMAW) Welding

27.2A 

Io = 100A @ 24.0V

35.2/31.6A 

Io = 200A @ 28V

Rated Input Current (A) 

                                             For LIFT TIG (GTAW) Welding

23.2A 

Io = 125A @ 15.0V

24.6/22.1A 

Io = 200A @ 18V

Rated Output for STICK (SMAW) Welding

24.0V, 100A @ 45%

28V, 200A @ 20%

Rated Output for LIFT TIG/HF TIG (GTAW) Welding

15.0V, 125A @ 50%

18V, 200A @ 25%

Duty Cycle (%)

45% @ 100A 

20% @ 200A

Welder Type

Inverter Power Source

Output Terminal Type

Heavy Duty Dinse

TM

 50

Classification

Protection Class

IP21S

Standards

CSA E60974-1   

EN50199

Cooling Method

Fan Cooled

Dimensions and Weight

Welding Power Source Mass

22 lb. (10 kg)

Welding Power Source Dimensions (Height x Width x Depth)

H 9.0” x W 5.3” x D 17.7”

(H230mm x W135mm x D450mm)

Summary of Contents for ET 201i DC

Page 1: ...Art A 13034 3163339 English Canadien Fran ais esab com ET 201i DC Inverter Arc Welder Operating Manual Revision AA Issue Date March 30 2016 Manual No 0 5452...

Page 2: ...refore please 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 COMP...

Page 3: ...TX 76208 www esab com Copyright 2015 by ESAB All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume...

Page 4: ...ereof contained in this manual and accompany ing labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked perio...

Page 5: ...conform ment la description contenue dans ce manuel les tiquettes d accompagnement et ou les feuillets d information si l quipement est install op r entretenu et r par selon les instructions fournies...

Page 6: ...em 3 9 3 09 LIFT TIG GTAW Setup 3 10 3 10 HF TIG GTAW Setup 3 12 3 11 When You Finish Using the Regulator 3 14 3 12 Storage of the Regulator 3 14 SECTION 4 OPERATION 4 1 4 01 Instruction 4 1 4 02 Fron...

Page 7: ...ortion 4 12 4 23 Overcoming Distortion Effects 4 12 SECTION 5 SERVICE 5 1 5 01 Maintenance and Inspection 5 1 5 02 STICK SMAW Welding Problems 5 2 5 03 TIG Welding Problems 5 3 5 04 Power Source Probl...

Page 8: ...TABLE OF CONTENTS This Page Intentionally Blank...

Page 9: ...protected 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 such as safety glass...

Page 10: ...ve 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...

Page 11: ...eplate attached to the machine is identified only by the specification or part number printed on the shipping container Record these numbers for future reference 2 03 Receipt of Equipment When you rec...

Page 12: ...6 4 Amps 12 3 11 1 Amps Maximum Input Current l1 max for STICK SMAW Welding 27 2 Amps 35 2 31 6 Amps Maximum Input Current l1 max for LIFT TIG HF TIG GTAW Welding 23 2 Amps 24 6 22 1 Amps Single Phase...

Page 13: ...prove or revise the specifications or design of this or any product without prior notice Such updates or changes do not entitle the buyer of equip ment previously sold or shipped to the corresponding...

Page 14: ...ET 201i DC INTRODUCTION 0 5452 2 4 This Page Intentionally Blank...

Page 15: ...tance of the human body and the insulation properties of accessories Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity...

Page 16: ...connections should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever nece...

Page 17: ...A could occur if 253VAC or higher is applied to the Primary Power Cable Model Primary Supply Lead Size Factory Fitted Minimum Primary Current Circuit Size Vin Amps Current Duty Cycle LIFT TIG HF TIG G...

Page 18: ...tection measures The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the bo...

Page 19: ...reasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the work piece to earth should be made by direct connection to the work piece but in some...

Page 20: ...trodes welding current at any one setting would vary according to the type of electrode in use The operator should use the welding current range values as a guide then fine tune the welding current to...

Page 21: ...electrode manufacturer for specific polarity recommendations 3 Connect the ground work clamp to your workpiece 4 Plug the power cable into the appropriate outlet and turn the switch to the ON positio...

Page 22: ...ng Pressure Gauges for Compressed Gas Service b Low pressure gauges must be UL recognized for the class of regulator they are being used on according to UL252A WARNING DO NOT use a regulator that deli...

Page 23: ...equipment 3 08 Leak Testing the System Leak test the system before putting into operation 1 Be sure that there is a valve in the downstream equipment to turn off the gas flow 2 With the cylinder valv...

Page 24: ...erminal Dinse 50 Negative Output Terminal Dinse 50 Art A 09785_AB Set Welding Current as specified by the Electrode Manufacturer Secure the gas cylinder in an upright position by chaining it to a stat...

Page 25: ...be around the valve regulator seat area 5 Install the regulator for details of VICTOR regulator please refer to 3 07 and tighten with a wrench 6 Connect one end of the supplied gas hose to the outlet...

Page 26: ...minal Dinse 50 Negative Output Terminal Dinse 50 Art A 10100_AB Set Welding Current as specified by the Electrode Manufacturer Secure the gas cylinder in an upright position by chaining it to a statio...

Page 27: ...be around the valve regulator seat area 5 Install the regulator for details of VICTOR regulator please refer to 3 07 and tighten with a wrench 6 Connect one end of the supplied gas hose to the outlet...

Page 28: ...ounterclockwise to release the ten sion on the adjusting spring 5 Check the gauges after a few minutes for verification that the cylinder valve is closed completely 3 12 Storage of the Regulator When...

Page 29: ...it the specific application Refer to the electrode manufacture s literature for further information 4 02 Front Panel Front Panel The welding power source is protected by a self re setting thermostat T...

Page 30: ...ontrol Knob F At any time while welding if the TIG Torch Trigger Switch is depressed and released the arc will extinguish immediately D Process Selection Switch Switches between STICK SMAW LIFT TIG GT...

Page 31: ...y Voltage to the Power Source 4 03 Welding Current Control Explanation 15 Amp Outlet The mains power 15 Amp circuit breaker or fuse should not trip at this Weld Current value when STICK welding The en...

Page 32: ...d by using the correct electrodes preheating using higher current settings using larger electrodes sizes short runs for larger electrode deposits or tempering in a furnace Manganese Steels The effect...

Page 33: ...ogen all position electrode used when quality is an issueorforhard to weldmetals Ithasthecapabilityofproducing more uniform weld metal which has better impact properties at low temperatures Cast Iron...

Page 34: ...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 LPM Butt Corner 90 115 90 110 Lap Fi...

Page 35: ...ertical position fillet weld Figure 4 9 Overhead position butt weld Art A 07687 Figure 4 3 Flat position down hand butt weld Art A 07688 Figure 4 4 Flat position gravity fillet weld Art A 07689 Figure...

Page 36: ...lded should be clean and free of rust scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in Figure 4 11 Gap varies from 1 16 1 6mm to 3 16 4 8mm dependi...

Page 37: ...iece This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough A low amperage will accentuate it This freezing on of the tip may be overcome by sc...

Page 38: ...uent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4 14 The width of weave should not be more than three times the core wire diameter...

Page 39: ...Figure 4 19 Examples of vertical fillet welds 2 Vertical Down The E7014 electrode makes welding in this position particularly easy Use a 1 8 3 2mm electrode at 120 amps The tip of the electrode is he...

Page 40: ...line can be attempted hear 4 22 The Cause of Distortion Distortion is cause by A Contraction of Weld Metal Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature This...

Page 41: ...stortion Figure 4 24 shows a simple application By removing the heating source from b and c as soon as welding is completed the sections b and c will contract at a similar rate thus reducing distortio...

Page 42: ...ET 201i DC OPERATION 0 5452 4 14 This Page Intentionally Blank...

Page 43: ...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 sens...

Page 44: ...se smaller diameter electrode C Allow wider gap D Use correct build up sequence 4 Portions of the weld run do not fuse to the surface of the metal or edge of the joint A Small electrodes used on heavy...

Page 45: ...ing 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 flutters dur...

Page 46: ...ary supply voltage has not been switched ON B The Welding Power Source switch is switched OFF C Loose connections internally A Switch ON the Primary supply voltage B Switch ON the Welding Power Source...

Page 47: ...Dx6 ID W7003079 16 Connector Gas Outlet W7003212 17 Output Terminal 50mm dinse W7003020 18 Socket 8 Pin Cable W7003220 19 Gas Solenoid W7003033 20 Current Sensor W7003076 Current Sensor 21 Base Panel...

Page 48: ...ET 201i DC KEY SPARE PARTS 0 5452 6 2 2 5 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 20 22 23 24 25 26 Art A 10104_AC 27 5 1...

Page 49: ...ft 600285 Slider Current Control with Torch Switch 15ft suits 7 8 to 1 1 8 dia 17 TIG Torch Handle 10 4009 Slider Current Control with Torch Switch 15ft suits 1 1 8 to 1 3 8 dia 26 TIG Torch Handle 10...

Page 50: ...OT MAX 4 POT MIN 5 6 START RTN 7 START 8 4 1 1 2 PANEL CUR DEMAND 3 4 10 CURRENT DEMAND 9 DOWN SLOPE ARC FORCE 8 2T 4T 7 N A 6 FAULT LED 5 HF TIG 4 STICK 3 VOLTAGE TEST 2 15VDC 1 15VDC 1 10 1 RED BLAC...

Page 51: ...This Page Intentionally Blank...

Page 52: ...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...

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