ESAB Ruffian ES 150G EDW User Manual

Ruffian ES 150G EDW
Engine Driven Welder MMA 150A
Instruction manual
Valid for: Serial number:
0463 905 001 GB 20220907 HA229YY-XXXXXX

ESAB Ruffian ES 150G EDW Specifications

General

Input Voltage	230 V
Input Current	16 A
Input Frequency	50/60 Hz
Rated Input Current	16 A
Electrode Size	1.6-4.0 mm
Protection Class	IP23

Summary

SAFETY

Meaning of Symbols

Explains hazard symbols like Danger, Warning, Caution, and their meanings.

General Safety Precautions for Arc Welding

Provides essential safety measures for arc welding processes to protect personnel.

Fires and Explosions Prevention

Details precautions to prevent fires and explosions caused by welding heat, sparks, and hot metal.

Electrical Shock Hazards

Outlines critical safety measures to prevent severe injury or death from electrical shock.

Electric and Magnetic Fields

Discusses potential dangers of EMF and procedures to minimize exposure during welding.

Fumes and Gases Safety

Covers risks associated with welding fumes and gases, emphasizing ventilation and respiratory protection.

Cylinder Handling Safety

Provides safety guidelines for handling compressed gas cylinders to prevent rupture and injury.

Falling Equipment Hazards

Warns about the dangers of falling equipment and provides safe lifting practices.

Equipment Maintenance Safety

Stresses the importance of proper maintenance to prevent injuries or death from faulty equipment.

Additional Safety Information

Lists recommended publications for further safety information on welding and cutting.

General Safety Precautions for Engines and Generators

Moving Parts Hazards

Highlights hazards from moving parts like fans and belts and provides preventative measures.

Engine Exhaust Gases Safety

Warns about the toxicity of engine exhaust gases and the need for proper ventilation.

Engine Fuel Safety

Addresses the flammability of engine fuel and precautions during fueling.

Battery Acid Hazards

Details hazards associated with battery acid and explosive gases, emphasizing safety when working with batteries.

User Responsibility

California Proposition 65 Warning

INTRODUCTION

Overview

Introduces the RUFFIAN ES 150G EDW as a DC stick welder and AC generator.

Equipment

Lists the items supplied with the EDW unit.

TECHNICAL DATA

Welder Specifications

Details technical specifications for the welding functions of the ES 150G EDW.

Generator Specifications

Provides technical specifications for the AC generator output of the unit.

Engine Specifications

Lists the brand, model, power, and other details of the engine.

General Specifications

Covers general aspects like operating temperature, dimensions, and weight.

Application Class

Explains the meaning of the 'S' symbol for application class and increased electrical hazard.

Fuel Consumption Curves

Presents a graph showing typical fuel consumption under welding or auxiliary loads.

Simultaneous Output Power

Shows the relationship between welding current and available auxiliary output power.

INSTALLATION

Location

Guides on positioning the welder for proper cooling airflow and stability.

Lifting Instructions

Explains how to manually and mechanically lift the equipment safely.

Overall Tubular Frame Dimensions

Provides detailed measurements of the unit's tubular frame.

Assembly Running Gear

Lists the components and quantities required for assembling the running gear.

Engine Prestart Checks

Details essential checks to perform on the engine before starting operation.

OPERATION

Engine Control Devices

Identifies and explains the function of the engine's control elements.

Front Panel Connections and Control Devices

Describes the layout and function of the front panel controls and connections.

Connecting the EDW to Ground

Details the process and safety requirements for grounding the welder unit.

Connecting Output Terminals

Explains how to connect welding cables to the positive and negative output terminals.

Selecting and Preparing Welding Cables

Provides guidance on choosing the correct gauge and preparing welding cables.

Starting and Stopping the Engine

Describes the step-by-step procedure for starting and stopping the engine.

Operating the Welder

Explains how to turn on and adjust the welder settings for operation.

Operating AC Auxiliary Power (Generator)

Guides on how to use the generator function and connect electrical equipment.

AC Auxiliary Power Guide

AC Auxiliary Power Supplied by the Generator

Advises on limiting load to 90% of nominal output and starting motor loads first.

AC Auxiliary Power Required by the Load

Explains how to calculate and check load wattage against generator capacity.

Approximate AC Auxiliary Power Requirements by Loads

Lists typical starting and running watts for various job site equipment.

MAINTENANCE

Engine Routine Maintenance

Outlines a maintenance schedule for the engine based on usage hours or time.

Engine Oil Change

Provides detailed steps for changing the engine oil, including capacity and disposal.

Air Filter Element Maintenance

Explains how to maintain the air filter system, including cleaning and replacement.

Spark Plug Maintenance

Details how to maintain the spark plug, including gap adjustment and replacement.

Welder Routine Maintenance

Schedules routine checks and maintenance for the welder components.

Cleaning Instruction

Provides instructions and safety precautions for cleaning the equipment.

TROUBLESHOOTING

Welder Troubleshooting

Lists common welding faults and their corrective actions.

AC Auxiliary Power Troubleshooting

Addresses issues with the AC auxiliary power output and their solutions.

Engine Troubleshooting

Provides corrective actions for common engine starting and running problems.

ERROR CODE

ORDERING SPARE PARTS

APPENDIX

Block Diagram

Presents a schematic block diagram of the equipment's electrical system.

Ordering Numbers

Lists part numbers for ordering the welder, manuals, and related documentation.

Accessories

Lists available optional accessories for the ES 150G EDW welder.