EAS IV
F-15-261
October,1995
INSTRUCTION MANUAL
EAS IV
ELECTRONIC ARC STARTER
This manual provides complete Instructions for the following unit:
ESAB P/N 34839 - EAS IV Electronic Arc Starter
Á ENEE
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and
safe practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc
Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this
equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these
instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure
to read the Safety Precautions before installing or operating this equipment.
E
Be sure this information reaches the operator. ESAB ESAB Welding &
Cutting Products
You can get extra copies through your supplier.
This equipment will 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. Do NOT use defective equipment. Immediately replace
parts that are broken, missing. worn. distorted or contaminated. Should repair or replacement become necessary.
the manufacturer recommends that a telephone or written request for service advice be made to the Authorized
Distributor from whom purchased.
Do NOT alter this equipment or any of its parts without the prior written approval of the manufacturer. The user of
this equipment shall have the sole responsibility for any malfunction which results from improper use. faulty
maintenance, damage. improper repair or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.
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WARNING: These Safety Precautions are for
your protection. They summarize precautionary
information from the references listed in Addi-
tonal Safety Information paragraph. Before performing any
installation or operating procedures. be sure to read and follow
the safety precautions listed below as well as all other manu-
ais, material safety data sheets, labels, etc. Failure to observe
Safety Precautions can result in injury or death,
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging pro-
‚7 cesses are noisy and require ear protec-
EZ tion. The arc, like the sun, emits ultravio-
t (UV) and other radiation and can in-
jure skin and eyes. Hot metal can cause burns. Training
in the proper use of the processes and equipment is
essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area. even if welding helmets. face shields. and goggles are
also required.
. Use a face shield fitted with the correct filter and cover
plates 10 protect your eyes. face. neck. and ears from
sparks and rays of the arc when operating or observing
operations. WARN bystanders not to watch the arc and not
to expose themselves 10 the rays of the electric arc or hot
metal.
3. Wear flameproof gauntlet type gloves. heavy long-sleeved
shirt, cuttless trousers, high-topped shoes, and a welding
helmet or cap for hair protection. to protect against arc rays
and hot sparks or hot metal. A flameproof apron may also
be desirable as protection against radiated heat and sparks.
+. Hot sparks or metal can lodge In rolled up sleeves. trouser
cufts. or pockets. Sleeves and collars should be kept
buttoned. and open pockets eliminated from the front of
clothing.
5. Protect other personne! from arc rays and hot sparks with
a suitable non-flammable partition or curtains.
ho goggles over safety glasses when chipping slag or
nding. Chipped slag may be hot and can fly far. Bystand-
и should also wear goggles over safety glasses.
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— FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and explo-
sions. Therefore:
1. Remove all combustible materials well away from the work
area or cover the materials with a protective non-flammable
covering. Combustible materials include wood. cloth. saw-
dust, liquid and gas fuels. solvents. paints and coatings.
paper. etc.
Hoi | sparks or hot metal can fall through cracks or crevices
in floors or wall openings and cause a hidden smoldering
fire or fires on the floor po Make certain that such
openings are protected from hot sparks and metal.
3. Do not weld. cut or perfor m other hot work until the
orkpiece has been completely cleaned so that there are
no substances on the workpiece which might produce
flammable or toxic vapors. Do not do hot work on closed
containers. They may explode.
+. 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.
Го
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. Do not use equipment beyond its ratings. For example.
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations. inspect the work area to make
certain there are no hot sparks or hot metal which could
cause a later fire. Use fire watchers when necessary.
. For additional information. refer to NFPA Standard 518.
"Fire Prevention in Use of Cutting and Welding Processes.”
available from the National Fire Protection Association,
Batterymarch Park, Quincy. MA 02269.
ES
ELECTRICAL SHOCK -- Contact can
cause severe injury or death. Do NOT use
AC output in damp areas, if movement is
confined. or if danger of falling exists.
Put on dry. hole-free gloves before turn-
e ing on the power. Also:
1. Be sure the power source frame (chassis) is connected to
the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or missing
connection can expose the operator or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or damaged
cables.
5. Keep everything dry
torch electrode ho
immediately.
6. Make sure that you are well insulated, Ds ly when
standing on metal or working in tight quarters or in a damp
cluding clothing. work area. cables.
der ane power source. Fix water leaks
area. Wear rubber-soled shoes and stand on adi y board or
insulating platform.
/. Turn oft the power before removing your gloves.
8. Refer to ANSI ASC Standard Z49.1 (see listing below) for
specific grounding recommendations. Do not mistake the
work lead for a
a ground cable.
ELECTRIC AND MAGNETIC FIELDS --
May be dangerous. Electric current flow-
ing through any conductor causes local-
ized Electric and Magnetic Fields (EMF).
Welding and cutting current creates EMF
around welding cables and welding m
chines. Therefore:
1. Welders having pacemakers should consult their physician
before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible
B. Never coil the torch or work cable around your body,
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away from
your body as possible.
1.
FUMES AND GASES --Fumes and gases,
can cause discomfort or harm, particu-
larly in confined spaces. Do not breathe
fumes and gases. Shielding gases can
cause asphyxiation. Therefore:
Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut. or gouge on
materials such as galvanized steel, stainless steel, copper.
zinc. lead. beryllium. or cadmium unless positive mechani-
cal ventilation is provided. Do not breathe fumes from these
materials.
Do not operate near degreasing and spraying operations.
The heat or arc rays can react with chlorinated hydrocarbon
vapors to form phosgene. a highly toxic gas. and other
irritant gases.
‚ If you develop momentary eye. nose. or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to improve
ventilation in the work area. Do not continue to operate if
physical discomfort persists.
. Refer to ANSHASC Standard 249.1 (see listing below) for
specific ventilation recommendations.
CYLINDER HANDLING -- Cylinders. if mis-
handled, can rupture and violently re-
lease gas. Sudden rupture of cylinder,
valve, or relief device can injure or kill
Therefore:
. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from the
compressed gas cylinder. Do not use adaptors. Maintain
hoses and fittings in good condition. Follow manufacturer's
operating instructions for mounting regulator to a com-
pressed gas cylinder.
. Always secure cylinders in an upright position by chain or
strap to suitable hand trucks. undercarriages. benches,
walls, post. or racks. Never secure cylinders to work tables
or fixtures where they may become part of an electrical
Circuit.
When not in use. keep cylinder valves closed. Have valve
protection cap in place if regulator is not connected. Secure
and move cylinders by using suitable hand trucks. Avoid
rough handling of cylinders.
Locate cylinders away from heat, sparks. and flames.
Never strike an arc on a cylinder.
. For additional information, refer to CGA Standard P-1.
"Precautions for Safe Handling of Compressed Gases in
Cylinders." which is available from Compressed Gas Asso-
ciation, 1235 Jefferson Davis Highway. Arlington. VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or im-
properly maintained equipment can cause
injury or death. Therefore:
. Always have qualified personnel perform the installation.
troubleshooting. and maintenance work. Do not perform
any electrical work unless you are qualified to perform such
work,
2, Before performing any maintenance work inside a power
source. disconnect the power source from the incoming
electrical power.
3. Maintain cables. grounding wire. connections. power
cord. and power supply in safe working order. Do not
operate any equipment in faulty condition,
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles. oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and
in good repair.
6. Use equipment only for its intended purpose. Do not
modify It in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for elec-
tric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging.” Form 52-529.
The following publications. which are available from the
American Welding Society, 550 N.W. LeJuene Road, Mi-
ami, FL 33126. are recommended to you:
1. ANSI ASC Z49.1 - "Safety in Welding and Cutting”
2. AWS C51 - "Recommended Practices for Plasma Arc
Welding”
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting”
4. AWS C5.3 - "Recommended Practices for Air Carbon Arc
Gouging and Cutting”
5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding”
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding”
7. AWS SP - "Safe Practices” - Reprint, Welding Handbook.
8. ANSFAWS F4.1. "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
This symbol appearing throughout this manual
means Attention! Be Alert! Your safety is
involved.
The tollowing definitions apply to DANGER. WARNING,
CAUTION found throughout this manual:
Used to call attention to immediate haz-
dh BYTE ards which, if not avoided. will result in
DT immediate. serious personal injury or loss
of life.
y Used to call attention to potential hazards
E which could result in personal injury or loss
of life.
@ Used to call attention to hazards which
% could result in minor personal injury,
SCOPE
This manual has been prepared especially for use in
familiarizing personnel with the design. installation, op-
eration. maintenance, and troubleshooting ofthe EAS IV.
All information presented herein should be given careful
consideration to assure optimum performance of this
equipment.
1.2 DESCRIPTION
The EAS IV is an electronic TIG (GTAW) arc starting
device specially designed for use with the SVI-300i power
source. The designis such that it enables the operator to
perform de non-touch TIG applications in a single work
cell without having the power source inthe work cell. The
EAS IV's electronic arc starting device is designed for use
in de straight polarity applications where RF interference
is critical. InTIG. the EAS IV's patented electronic design
utilizes adc high voltage spark to initiate the transfer of the
power arc to the workpiece without fear of high frequency
radiation problems. Since conventional high frequency
arc current is not used. it allows TIG arc starting when
working with or around equipment which is susceptible to
RF interference. The external power requirements forthe
operation of the arc starter is supplied from 24 V ac from
the power source and an arc voltage sensing relay circuit
is used to remove the high voltage de arc after the main
power arc is established.
Table 1-1. EAS IV Specifications
300 amps @ 60°.
250 amps @ 100°,
Power Source
CURRENT RATING DIMENSIONS NET WEIGHT/
MODEL | 6 duty cycle (Tig) | INPUT POWER (Lx W x H) SHIPPING WEIGHT
EAS IV | 400 amps @ 40°. 24 V ac from 16.2" x 6.1" x 14.4" 30 Ibs (13.6 kg)
(412 mm x 155 mm x 366 mm)
(includes handle and feet)
35 Ibs (15.9 kg)
INSTALLATION
2.1 GENERAL
Select a suitable location to mountthe arc starting unit so
that the unit cannot be accidentally damaged.
Electric shock can kill! Ensure the
® line (wall) disconnect switch or cir-
y cuit breaker is open before setting up
the electronic arc starter.
2.2 ELECTRICAL INPUT CONNECTIONS
The EAS М 15 equipped with two cables with twist-lock
connectors and an interconnecting control cable. Pro-
ceed as follows (see figure 2-1):
A. Selectanappropriate site to locate the SVI-300i and
mount the EAS IV,
1) Connectthe negative (-) cable of the EAS IV to
the negative (-) terminal of the SVI-3001.
Connect the positive (+) cable of the EAS IV to
the positive (+) terminal of the SVI-3001.
B. Plugthe 14 pincontrol cable fromthe EAS IV into the
SVI-300i receptacle on the rear panel.
C. Plug the TC-2B, HC-3B. or FC-5B remote control
into the EAS IV 14 pin amphenol connection on the
front panel.
D. fusing an air-cooled torch. install proper adapter, if
required. into the torch receptacle on the front of the
EAS IV and install T1G torch.
E. Run gas supply hose to the rear of the EAS IV and
make connection at "GAS IN." Connection for gas
supply to torch should be made at the gas torch
connection "Shield Gas to Torch.”
When connecting to gas and water supplies, use only
non-conductive hose. Do NOT use metallic piping in
the water discharge from the arc starter. Do NOT use
water with high mineral content; this can cause semi-
conducting which may affect the torch.
>
SECTION 2
TC-2B
HC-3B
FC-5B
Adapter
19708 for HW-9 & HW-24 ^^.
19709 for HW-26 e
19710 for HW-17
7 Air-Cooled
TIG Torch
Torch with: —
Twist Lock Connector
SVI-300i Remote Control —
Water Supply Outlet
Water Supply Inlet
May be continuous
or through WC-8 or WC-9
Coolant Circulator,
he
Les I
Ci
To SVI-300 (-)
To SVI-300 (+)
Work Cable
Figure 2-1. Interconnection Diagram
INSTALLATION
Water-Cooled y
TIG Torch
Gas
OPERATION
If the EAS IV was installed properly. you should have
straight dc polarity current. If you find that the current
polarity is reversed. either the power cables from the SVI-
3001 power source to the EAS IV or the WORK and
TORCH connections are reversed.
3.2 POWER SOURCE SETTINGS
On the SVI-3001:
A. Set the MIG TIG STICK switch in the TIG position.
B. Setthe CONTROL andthe CONTACTOR switches
in the REMOTE position.
C. Set the digital meter switch to AMPS.
D. Set the CURRENT control knob to desired maxi-
mum setting.
3.3 EAS-IV SETTINGS
A. Setthe PRE-FLOW and the POST-FLOW knobs to
the desired time settings. Turn the knobs clockwise
to increase the time.
B. ARC START LIFT ARC switch. Arc start provides
the high voltage to the torch so that the arc can be
started without touching the electrode to the
workpiece. Lift arc bypasses the high voltage start.
Touch the electrode to the workpiece and then lift off
the electrode slightly to start the arc.
MAINTENANCE
Electric shock can kill! Ensure the line
» (wall) disconnect switch or circuit
breakeris open before attempting any
inspection or work on the inside of the
electronic arc starter. Always wear safety goggles
with side shields when blowing out the plumbing
lines with low pressure air.
If this equipment does not operate properly, stop
work immediately and investigate the cause of the
malfunction. Maintenance work must be performed
by an experienced person, and electrical work by a
trained electrician. Do not permit untrained person-
nel to inspect, clean, or repair this unit. Use only
recommended replacement parts.
4.2 INSPECTION AND CLEANING
since there are no moving parts in the arc starter. main-
tenance consists mainly of keeping the interior of the
cabinet clean. Periodically. remove the cover from the
cabinet, and wearing proper eye protection. blow accu-
mulated dust and dirt from the air passages and the
interior components, using clean low pressure air. The air
passages to the interior of the unit must be free of dirt to
ensure adequate circulation of natural air flow. Thelength
of time between cleaning willdepend onthe location of the
unit and the amount of dust in the atmosphere.
CD
5.1 GENERAL
7 | \@ WARNING
% Electric shock can kill! Ensure the
line (wall) disconnect switch or cir-
cuit breaker is open before attempt-
ing any inspection or work on the
inside of the electronic arc starter. Always wear
safety goggles with side shields when blowing out
the plumbing lines with low pressure air.
Check the problem against the symptoms in the following
troubleshooting guide. The remedy may be quite simple.
Ifthe cause cannot be quickly located. shut off the unit and
perform a simple visual inspection of all components and
wiring. Check for secure terminal connections, loose or
burned wiring or components. bulged or leaking capaci-
tors. or any sign of damage or discoloration.
Table 5-1. Troubleshooting Guide
PROBLEM POSSIBLE CAUSE
REMEDY
1. No spark. a. No power source open | a.
circuit voltage.
Check power source output voltage at the starter work:
welder terminals.
b. Defective PC board D.
(PCB1) or leaky block
diode bridge (BR1 or
BR2).
It the input voltage to the converter is 15 V dc. then the
output voltage should be 2800-3000 V dc. (Use high
voltage probe for this test.) If converter output voltage is
out of spec.. replace PCB1 as determined by test.
c. Low torch cable С.
assembly and work
cable insulation
resistance.
Check the dc high voltage out of the starter (Torch-Work)
with and without weiding torch and work cables connected.
The V dc should be 2800-3000 V dc in both cases. If not,
change the torch assembly and or the work cables.
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TROUBLESHOOTING
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Figure 5-1. EAS IV Schematic Diagram
SECTION 5 | TROUBLESHOOTING
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D-35769
Figure 5-2. EAS IV Wiring Diagram
Replacement parts are illustrated in figures 6-1 thru 6-3.
Always provide the series or serial number of the unit on
which the parts will be used. The serial number is
stamped on the unit nameplate.
To assure proper operation. it is recommended that only
genuine ESAB parts and products be used with this
equipment. The use of non-ESAB parts may void your
warranty.
REPLACEMENT PARTS
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 instructions when
ordering replacement parts.
Refer to the Communications Guide located on the last
page of this manual for a list of customer service phone
numbers.
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SECTION 6
REPLACEMENT PARTS
Figure 6-1. Front View/Back View
ITEM
QTY PART CIRCUIT
NO. REQ. NO. | DESCRIPTION SYMBOL
1 1 35765 COVER, TOP
2 1 35766 PANEL, SIDE
3 1 951811 HANDLE
4 1 58V58 АОАРТ ВА-С"Е 1/4 МРТ
5 2 58V75 ADAPT B/A-W"F 1/4 NPT
6 1 32192 COVER OUTPUT PRINTED |
7 2 993426 GROMMET 1.5" I.D. |
SECTION6 REPLACEMENT PARTS
18 17
6 16 7
5
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2 >
| | 8
i |
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1 = В
| и | 10
1 | ||
So, =e ый Чей / nr E Ban
17
10 12
11
19
12 15 14 13
Figure 6-2. Right Side View (Cover Removed)
ITEM TY PART CIRCUIT
NO. REO. NO. DESCRIPTION SYMBOL
1 2 13733936 CONNECTOR, OUTPUT J2, J3
2 1 5875 ADAPT, B/A-W*'F 1/4 NPT
3 2 13733935 PANEL, RECEPTACLE 2-1/0
4 i 35768 BUSBAR
5 i 30612 OUTPUT TERMINAL BLOCK
6 i 634518 SWITCH, DPDT 51
7 1 35772 CABLE ASSY
8 1 32180 CABINET
Mi 1 951634 VALVE SOLENOID 24V SOL1
10 3 950510 NIPPLE 4/16, 1/4 NPTF
11 2.16 HOSE, BRAIDED, .187 1.D. VINYL
12 4 182W12 MOUNTING FOOT
13 1 17250005 RESISTOR, 5 OHM R3
14 2 952041 DIODE BRIDGE BR1, BR2
15 1 952039 CONTACTOR K1
16 1 36 W76 STRAIN RELIEF
17 2 995104 METAL OXIDE VARISTOR 150V 104 MOV1, 2
18 1 32191 CONTROL PAMEL PRINTED
19 2 13732313
CABLE CLAMP
SECTION 6 oie ñ _— REPLACEMENT PARTS
7
Figure 6-3. Top View (Cover Removed)
ITEM QTY PART CIRCUIT
NO. REQ. NO. DESCRIPTION SYMBOL
1 2 13730611 KNOB
2 2 951511 POTENTIOMETER 2 MOHM 2W H33, R34
3 1 636667 RECEPTACLE 14 PIN "X" ROTATION | Ji
4 1 635686 TERMINAL STRIP 8 POS 181
5 1 38026 BOARD, PC ASSY | PCB1
6 1 950487 TERMINAL STRIP 2 POS | TB2
7 1 952040 TRANSFORMER, 24V T1
COMMUNICATIONS GUIDE
A. CUSTOMER SERVICE QUESTIONS: Telephone: (803) 664-5540 FAX: (8001 634-7548
Order Entry — Product Availability — Pricing Order Changes Hours: 8:30 AMto 5:00 PMEST
B. ENGINEERING SERVICE: Telephone: (803) 664-4416: FAX: (800) 446-5693
Welding Equipment Troubleshooting Warranty Returns Hours: 7:30 AM to 5:00 PM EST
C. TECHNICAL SERVICE: Telephone: 1800) ESAB-123 FAX: (803) 664-4229 or -4452
Part Numbers Technical Applications Hours: 7:30 AM 10 5:00 PMEST
Performance Features Technical Specifications
D.LITERATURE REQUESTS: Telephone: (503) 661-5501. FAX: 1803) 664-5546
Hours: 7:30 AM to 4:00 PMEST
E. WELDING EQUIPMENT REPAIRS: Telephone: (503) 664-4469 FAX: 18031 664-5557
Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING: Telephone: (803) 664-4237. FAX: 1503) 664-5575
Training School Information and Registrations Hours: 7:30 AM io 4:00 PM EST
G. WELDING PROCESS ASSISTANCE: Telephone: (503) 661-4248: FAX: (8031 664-4454
Hours: 7:30 AM to 4:00 PMEST
H.TECHNICAL ASST. CONSUMABLES: Telephone: (800: 934-9355
Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Hours: 7:30 AM to 5:00 PM EST
ESAB Welding & Cutting Products
PO Box 100545 Florence SC 29501-0545
F-15-261 10:95 1.5M Printed in U.S.A.
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