ESAB Aristotig255 AC/DC DTE 255 User manual

GB
Valid for serial no. 810−to 246−0457 784 201 GB 031110
Aristotig 255 AC/DC
DTE 255
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Equipment 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 TECHNICAL DATA 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Location and connection 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 OPERATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Controls and connections 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Remote control unit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Protection against overheating 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Control panel 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 MMA welding (Hand welding electrodes) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 TIG welding 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 Forced disconnection 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 MAINTENANCE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Check−up and cleaning 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING OF SPARE PARTS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 DIRECTIVE
DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S−695 81 Laxå, Sweden, gives its unreserved guarantee that welding
power source DTE 255 from serial number 833 complies with standard IEC/EN 60974−1, in accord-
ance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with standard
EN 50199 in accordance with the requirements of directive (89/336/EEC) and addendum
(93/68/EEC).
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Anders Birgersson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 1998−08−11
2 SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommen-
dations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well−acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
2. The operator must ensure that:
Sno unauthorized person is stationed within the working area of the equipment when it is
started up.
Sno−one is unprotected when the arc is struck
3. The workplace must:
Sbe suitable for the purpose
Sbe free from drafts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame−proof
clothing, safety gloves.
SDo not wear loose−fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK −Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES −Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS −Can injure eyes and burn skin.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE −Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION −Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
ESAB can provide you with all necessary welding protection and accessories.
WARNING!
Read and understand the instruction manual
before installing or operating.
Do not use the power source for thawing frozen pipes.
WARNING!
This product is solely intended for arc welding.
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3 INTRODUCTION
DTE 255 is a compact welding power source for two different welding methods.
It can be used for:
Swelding with tungsten electrodes (TIG), using direct or alternating current.
Smanual metal arc welding with coated electrodes (MMA), using direct or
alternating current.
DTE 255 is available in two designs:
Swith OKC connection for the TIG torch
Swith central connection for the TIG torch
Note: Remove the TIG torch when using the MMA method.
When TIG−welding, remove the electrode holder.
ESAB’s accessories for the product can be found on page 19.
3.1 Equipment
DTE 255 is delivered with:
SMains cable (3 m)
SReturn cable (5 m)
SGas hose
SHose clamps
4 TECHNICAL DATA
DTE 255
Permissible load at
25% duty cycle (MMA)
60% duty cycle (MMA)
100% duty cycle (MMA)
250 A / 30 V
200 A / 28 V
165 A
/
26 V
100% duty cycle (MMA)
50% duty cycle (TIG)
60% duty cycle (TIG)
100% duty cycle (TIG)
165 A / 26 V
250 A / 20 V
225 A / 19 V
170 A / 17 V
Setting range, TIG
Setting range, MMA
5−250 A, DC
5*−250 A, AC
5−250 A
Slope up 0 −10 s
Slope down 0 −10 s
Gas preflow, adjustable on the circuit board 0 −5 s
Gas postflow 3 −30 s
Open circuit voltage 70 −90 V DC
No−load power, MMA
No−load power, TIG
95 W
50 W
Useful power, P (at max. current MMA) 10 kW
Apparent power, S (at max. current MMA) 10.6 kW
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DTE 255
Power factor at max. current, MMA 0.93
Efficiency at max. current, MMA 0.75
Mains voltage 400 V +/−10% 3 phases
Mains frequency 50 −60 Hz
Welding cable, sectional area 35 mm2
Fuse, slow−acting 16 A
Mains cable, sectional area 4 x 2.5 mm2
Dimensions l x w x h 510 x 310 x 555 mm
Weight 45 kg
Application class
Enclosure class IP 23
*) The minimum current during AC welding depends on the alloy used for the aluminium plates and
their surface cleanliness.
Duty cycle
The duty cycle refers to the time as a percentage of a ten−minute period that you can weld at a cer-
tain load without overloading.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
5 INSTALLATION
The installation must be executed by a professional.
WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the user’s responsibility to take adequate precautions.
DTE 255 has mains voltage compensation, which means that +/−10% variation in
the supply voltage produces only +/−0.2% variation in the welding current.
To reduce the voltage drop resulting from the use of long welding cables, a cable
with a larger sectional area than the one indicated under Technical Data on page 5
can be used.
When the power source is started, the cooling fans work at a reduced rotation
speed, partly to reduce the amount of dirt that can be sucked in and partly to ensure
a lower noise level.
When the power source requires increased cooling, the fans work at a higher
rotation speed.
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5.1 Location and connection
SPlace the welding power source so that the cooling air in−and outlets remain
free.
SConnect the shielding gas (see fig. on page 7).
SConnect the TIG torch and the torch return cable, alternatively the welding and
return cable of the electrode holder (see fig. on page 7).
SMake sure the welding power source is connected to the right mains voltage and
that it is properly fused. Connect to earth according to applicable regulations.
Rating plate with connection data is located on the rear of the welding power
source.
The machine is now ready for use.
6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
6.1 Controls and connections
Central connection
AMains switch ON/OFF HMains voltage ON, LED
BConnection for remote control unit JWelding voltage ON, LED
CTorch connector LError / Overheating, LED
DConnection for electrode holder (MMA) MFlow guard, LED
(Functions when the cooling unit is
connected)
EOKC connection for TIG torch NConnection for shielding gas to the machine
FReturn cable connection OControl unit, digital display
GShielding gas connection PCentral connection for TIG torch
N.B. The positions C and G are dropped when the central connection is used.
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When the mains switching device is turned on, the diode (H) goes on.
When open circuit voltage is applied diode (J) goes on.
When an error occurs, for example overheating, diode (L) goes on.
When there is no water flow diode (M) goes on.
When there is a fault that can cause temporary high output voltage, the LED
switches off (J), (output voltage has been switched off). When idling for longer than
30 minutes, the output voltage is switched off and diode (J) goes out.
Restart by turning the switch (1) to TIG mode and then back to MMA mode.
6.2 Remote control unit
For both the TIG and MMA methods the welding current can be adjusted by way of a
remote control unit. The welding power source registers automatically when a
remote control unit is connected.
If the remote control is to include the whole current range, the current must be set to
max. on the welding power source.
Max. value = The reference value set on the welding power source.
6.3 Protection against overheating
Three thermal cut−outs prevent the power source being overloaded as a result of too
high temperature. If this should happen, the welding current is interrupted and the
yellow diode (L) goes on. (See page 7.)
When the temperature has gone down, the welding current circuit is reclosed and
the diode goes out.
6.4 Control panel
1Method selection switch SMMA welding (hand welding electrodes)
STIG, two−stroke (also for remote control)
STIG, four−stroke
STIG four−stroke with the possibility to shift
between two currents (shift function). See items 8
and 9 on page 9for setting of the two currents.
2Ignition selection switch SHF ignition
SLift−Arc ignition, see page 10.
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3Pulsing selection switch SNon−pulsed welding, d.c. and a.c.
SWelding with square−wave pulsing; d.c. and a.c.
SWelding with trapezi−form pulsing; d.c. and a.c.
4Polarity selection switch SAlternating current
SSquare−wave alternating current
SDirect current, negative electrode (normal in TIG
welding)
SDirect current, positive electrode
SDirect current, negative electrode, but with positive
electrode at the start (for example for 3.2 mm
electrodes, TIG welding).
5Potentiometer for Hot Start SFor setting and optimising the starting cycle with
regard to the electrode size.
TIG welding ( 10...500 ms )
MMA welding (100ms...2s)
6Potentiometer for Arc−Force SFor setting and optimising the Arc−Force function
(Anti−Stick), for MMA welding only.
7 Potentiometer SFor setting the slope−up time of the welding
current (0 to 10 seconds).
8Potentiometer I1 SFor setting the non−pulsed welding current and the
current pulse when welding with pulsed current.
9Potentiometer I2 SFor setting the background current for pulsed
welding and the lower current level when using the
shift function.
10 Potentiometer SFor setting the welding current slope−down (0 to
10 seconds).
11 Potentiometer SFor setting the gas postflow time (3 to 30
seconds).
12 Potentiometer for setting the fre-
quency This potentiometer has double functions:
SFor setting the pulse frequency between 0.3 and
300 Hz for pulsed welding with direct current.
SFor setting the a.c. frequency between 30 and 300
Hz for non−pulsed welding with alternating current.
N.B. When welding with pulsed alternating current,
the a.c. frequency is automatically set to 100 Hz!
The max. pulse frequency to be set is then 100 Hz!
13 Potentiometer for setting the bal-
ance This potentiometer has double functions:
SFor setting the balance between positive and
negative half−wave when welding with alternating
current to optimise the cleaning or the penetration.
(Turning right =>increased penetration.)
SFor setting the time relation between the
background and the peak current when welding
with direct current.
(Turning right =>longer pulse current time.)
N.B. When welding with pulsed a.c. the time
balance between the pulse current and the base
current will automatically be 50/50%.
The relationship between positive and negative
halfwave is adjusted in the same way as nonpulsating
AC welding.
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Position = MMA
In this position the welding power source is prepared for welding with coated
electrodes. The HF unit and the Lift−Arc are disconnected, and the hot−start function
is activated in order to supply incresaed current at the start.
Position = HF unit ON
When pressing the torch trigger the gas starts flowing, the HF unit goes on,
generating an electric spark between the electrode and the welding material, the gas
is ionised and an arc is produced. When the arc is stable, the HF unit will
automatically be disconnected.
Position = Lift−Arc
By Lift−Arc is meant that you place the torch with the electrode on the spot where
you want to start the welding, press the torch trigger and lift up the torch. In doing so
an arc is produced.
The current slowly increases up to the set value during the set “slope up” time. When
you want to finish welding, the contact is released and the current slowly decreases
to the set “slope down” time.
Place the electrode against the workpiece. Press in the torch trigger.
Tilt the torch a little, lift and an arc is produced. To stop, release the torch trigger.
Position Two/four−stroke
Two−stroke means that the arc is struck when the torch trigger is pressed and
extinguished when it is released.
Four−stroke means that it is not necessary to keep the torch trigger pressed while
the welding is going on. The arc is struck by pressing an releasing the switch and is
extinguished by repeating the action.
Four−stroke with the possibility to switch between two currents (switching function).
Through short activation of the burner cpontact, the switching function gives rise to
switching between two adjustable currents.
If the burner contact is kept pressed in the current starts to slope down.
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