ESAB Buddy Arc 200 User manual

GB
Valid for serial no. 01107072134, 011080759720463 266 001 GB 20110902
Buddyä
Arc 180
Arc 200
Instruction manual
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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Location 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Mains power supply 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Recommended fuse sizes and minimum cable area 7. . . . . . . . . . . . . . . . . . . . . . .
5 OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Connections 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Connection of welding and return cable 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Symbols and Control panels 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Overheating protection 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 MMA welding 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.1 Welding current setting 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.2 Striking the arc 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.3 Manipulation of electrode 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.4 Anti-electrode pick-up 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.5 Joint forms in MMA 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.6 Electrode selection 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 TIG welding 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.1 Welding current setting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.2 Striking an Arc “Live TIG- start” 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.3 Joint forms in TIG 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 MAINTENANCE 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Power source 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Welding torch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 FAULT-TRACING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING SPARE PARTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 DISMANTLING AND SCRAPPING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDER NUMBER 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 SAFETY
Users of ESAB 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 equipment. The following recommendations should be ob
served 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 equip
ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in
jury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
its operation
location of emergency stops
its function
relevant safety precautions
welding and cutting
2. The operator must ensure that:
no unauthorised person is stationed within the working area of the equipment when it is
started 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, such as safety glasses, flame-proof
clothing, safety gloves.
Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
Make sure the return cable is connected securely.
Work on high voltage equipment may only be carried out by a qualified electrician.
Appropriate fire extinquishing equipment must be clearly marked and close at hand.
Lubrication and maintenance must not be carried out on the equipment during operation.
WARNING
Do not use the power source for thawing frozen pipes.
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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 precausions when welding and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
Install and earth the unit in accordance with applicable standards.
Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
Insulate yourself from earth and the workpiece.
Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
Keep your head out of the fumes.
Use 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.
Protect your eyes and body. Use the correct welding screen and filter 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 materials nearby.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
Class A equipment is not intended for use in residential locations where
the electrical power is provided by the public low-voltage supply system.
There may be potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations, due to conducted
as well as radiated disturbances.
CAUTION
This product is solely intended for arc welding.
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Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical and/or
electronic equipment that has reached the end of its life must be disposed of at a
recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain
information on approved collection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
Arc 180 and Arc 200 are welding power sources intended for use with coated
electrodes (MMA welding) and TIG welding (Live Arc).
ESAB's accessories for the product can be found on page 17.
2.1 Equipment
The power source is supplied with:
3 meter welding cable with electrode holder
3 meter return cable with return clamp
instruction manual.
3 TECHNICAL DATA
Arc 180 Arc 200
Mains voltage 230 V 1∼$10%, 50/60 Hz 230 V 1∼$10%, 50/60 Hz
Primary current Imax 36 A 40.7 A
Setting range MMA 5 A / 20.2 V - 180 A / 27.2 V 5 A / 20.2 V - 210 A / 28.4 V
Setting range TIG 5 A / 10 V - 180 A / 17.2 V 5 A / 10.2 V - 210 A / 18.4 V
Permissible load at MMA
30 % duty cycle
35% duty cycle
60 % duty cycle
100 % duty cycle
180 A / 27.2 V
130 A / 25.2 V
100 A / 24.0 V
200 A / 28.0 V
135 A / 25.4 V
120 A / 24.8 V
Permissible load at TIG
35% duty cycle
60 % duty cycle
100 % duty cycle
180 A / 17.2 V
130 A / 15.2 V
100 A / 14.0 V
200 A / 18.0 V
135 A / 15.4 V
120 A / 14.8 V
Power factor at maximum
current
0.72 0.71
Efficiency at maximum current >80 % >80 %
Open-circuit voltage U0max 59.8 V 66.3 V
Operating temperature -10 to +40°C-10 to +40°C
Transportation temperature -20 to +55°C-20 to +55°C
Sound pressure at no-load <70 db (A) <70 db (A)
Dimensions lxwxh 310 x 140 x 230 mm 360 x 140 x 230 mm
Weight 6 kg 7.5 kg
Enclosure class IP 23S IP 23S
Application class
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Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at
a certain load without overloading. The duty cycle is valid for 40°C.
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.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
4 INSTALLATION
The installation must be carried out by a professional.
4.1 Location
Position the power source such that its cooling air inlets and outlets are not
obstructed.
4.2 Mains power supply
Make sure that the welding power source is connected to the
correct supply voltage and that it is protected by the correct
fuse rating. The outlet shall have a protective earth
connection.
Rating plate with supply connection data
4.2.1 Recommended fuse sizes and minimum cable area
Arc 180 Arc 200
Mains voltage 230V 1∼ $10%, 50/60 Hz
Mains cable area mm23 G 2.5 3 G 2.5
Phase current I1eff (TIG) 14.7 A 16.6 A
Phase current I1eff (MMA) 19.7 A 24.1 A
NOTE! Use the power source in accordance with the relevant national regulations.
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5 OPERATION
General safety regulations for handling the equipment can be found on
page 4. Read through before you start using the equipment!
5.1 Connections
1Control panel 4Mains power supply switch 1/O
2Connection (-) for return cable, welding
cable or TIG torch
5Connection for mains cable
3Connection (+) for return cable or welding
cable
5.2 Connection of welding and return cable
The power source has two outputs, a negative [-] terminal (2) and a positive [+]
terminal (3), for connecting welding and return cables.
For MMA process the output to which the welding cable is connected depends on
the type of electrode, please refer to electrode packaging for information relating to
the correct electrode polarity.
For optional TIG process, connect the TIG torch power cable to the negative [-]
terminal (2). Connect gas inlet nut to a regulated shielding gas supply.
Connect the return cable to the remaining welding terminal on the power source.
Secure the return cable's contact clamp to the work piece and ensure that there is
good contact.
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5.3 Symbols and Control panels
Arc 180
Arc 200
Power ON
Indicating lamp, white,
power supply ON
Overheating
Indicating lamp, yellow,
overheating
Scratch TIG MMA welding
5.4 Overheating protection
The welding power source has a thermal overload trip which operates if the
temperature becomes too high, interrupting the welding current and lighting a yellow
indicating lamp on the front of the power source. The thermal overload trip resets
automatically when the temperature has fallen.
5.5 MMA welding
Move process selector switch to desired welding process.
NOTE: Power source output is enabled.
Check welding cable polarity selection matches electrode requirements. Select
desired welding current level.
5.5.1 Welding current setting
The Arc 180 power source has an adjustable welding current from 5
to 180 Amps.
The Arc 200 has an adjustable value from 5 to 200 Amps.
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5.5.2 Striking the arc
MMA welding may also be referred to as welding with coated electrodes. Striking the
arc melts the electrode, and its coating forms protective slag.
If, when striking the arc, the tip of the electrode is pressed against the metal, it
immediately melts and sticks to the metal, rendering continued welding impossible.
Therefore, the arc has to be struck in the same way that you would light a match.
Quickly strike the electrode against the metal and then raise it to give an appropriate
arc length (approx. 2 mm). If the arc is too long, it will crackle and split before finally
going out completely. Once the arc has been struck, move the electrode from left to
right. The electrode should be at an angle of 60° to the metal.
5.5.3 Manipulation of electrode
In MMA welding, there are three motions to being matched in the end of electrode:
the electrode moving to the molten pool along axes [1]; a small oscillation maybe
neccessary to achieve the desired width of the melt pool [2]; the electrode moving
along welding way [3].
The operator can choose the manipulation of electrode based on welding joint sharp,
welding position, electrode spec, welding current and operation skill, etc.
electrode
weld
workpiece
1 electrode moving
2 the electrode oscilliation (right and left)
3 the electrode move along weld
5.5.4 Anti-electrode pick-up
If, during the welding, the electrode would get in direct contact (touching) with the
workpiece to form short circuit, the welding current will drop to a miminum to prolong
the life of the electrode.
5.5.5 Joint forms in MMA
Butt joint Corner joint Lap joint T joint
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