ESAB DTB 250 User manual

Valid from Serial NO 548 XXX--XXXX
0456 267 001 98.07.10
DTB 250
AC/DC SQUARE Wave
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Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung
Manuel d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções
Ïäçãßåò ÷ñÞóåùò

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Rätt till ändring av specifikationer utan avisering förbehålles.
Ret til ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner uten varsel forbeholdes.
Oikeudet muutoksiin pidätetään.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Ci riserviamo il diritto di variare le specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.
Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.
SVENSKA 3..............................................
DANSK 11................................................
NORSK 19................................................
SUOMI 27................................................
ENGLISH 35..............................................
DEUTSCH 43.............................................
FRANÇAIS 51.............................................
NEDERLANDS 59.........................................
ESPAÑOL 67..............................................
ITALIANO 75..............................................
PORTUGUÊS 83..........................................
ÅËËÇÍÉÊÁ 91.............................................

ENGLISH
TOCe -- 3 5 --
1 DIRECTIVE 36........................................................
2SAFETY 36...........................................................
3 INTRODUCTION 37...................................................
3.1 TECHNICAL DATA 37........................................................
4 INSTALLATION 38....................................................
4.1 Connecting to supply 38.......................................................
4.2 Wiring instructions 38.........................................................
5 OPERATION 39.......................................................
5.1 TIG welding with DC 41.......................................................
5.2 TIG welding with AC 41.......................................................
5.3 MMA welding with AC or DC 42................................................
6 MAINTENANCE 42....................................................
7 ORDERING OF SPARE PARTS 42......................................
ASSEMBLY INSTRUCTIONS 99...........................................
DIAGRAM 100............................................................
ACCESSORIES 101.......................................................
SPARE PARTS LIST 103...................................................

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bt10d12e
1 DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guaran-
tee that welding power source DTB 250 from serial number 548 complies with stan-
dard EN 60974--1, in accordance with the requirements of directive (73/23/EEC) and
addendum (93/68/EEC) and with standard EN 50199 in accordance with the require-
ments of directive (89/336/EEC) and addendum (93/68/EEC).
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Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336
Laxå 1995--10--25
2SAFETY
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 keep fumes and gases 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 ear defenders or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
GB

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3 INTRODUCTION
DTB 250 is a thyristor controlled dual power source, for AC and DC welding.
Two welding methods can be used: TIG or MMA.
DTB 250 is supplied with wheels at the rear and castors at the front, plus a shelf for
a gas bottle and a water cooling unit.
OKC coupling and power cable*.
(* Power cable for 400V mains supply or higher).
3.1 TECHNICAL DATA
Maximum load
AC/DC MMA
100% duty cycle 95A/24V
60% duty cycle 145A/26V
35% duty cycle 200A/28V
Maximum load
AC/DC TIG
100% duty cycle 95A/14V
35% duty cycle 200A/18V
20% duty cycle 250A/20V
Settings range TIG 5A/10V--250A/20V
Settings range MMA 20A/21V--200A/28V
Max. open circuit voltage 65V AC, 71V DC
MMA 200A AC
Power factor 0.69
Efficiency 0.63
TIG 250A AC
Power factor 0.62
Efficiency 0.51
Open circuit power 300W
AC balance 40--60%
Slope--up 0.5--10s
Slope--down 0.5--10s
Gas post--flow 0.5--30s
Enclosure class IP 21
Weight 145 kg
Dimensions lxbxh 1180/745/965
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This power source complies with the requirements of IEC 974--1 and EN 60974--1.
Equipment marked IP 21 is intended for indoor use.
GB

Connecting to supply
230V,60Hz
230V,50Hz
400V,50Hz
440V,60Hz
500V,50Hz
550V,60Hz
fig.1 bt10d001
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4 INSTALLATION
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.
DTB 250 can be configured for the following supply voltages:
230/400 and 500 V, 50 Hz
230/440 and 550 V, 60 Hz
1. Check that the welding power source is configured for the available supply
voltage. See the wiring instructions. The voltage is set at terminal block XT1.
2. For mains cable rating and fuse ratings, see Connecting to supply.
3. For manual metal arc welding (MMA) connect the welding cable and return cable
to the + and -- terminals to provide the electrode polarity required.
4. For TIG welding, connect the torch to the central socket.
5. Connect the return cable to the OKC terminal marked +.
6. Connect the gas and adjust to the desired flow rate.
7. If required, connect the water--cooling unit. Connect the cable to terminal block
XT5.
4.1 Connecting to supply
DTB 250 60Hz 50Hz 50Hz 60Hz 50Hz 60Hz
Voltage (V) 1x230 1x230 1x400 1x440 1x500 1x550
Primary current (A) 62 68 43 40 34 33
Fuse, slow (A) 50 50 25 25 20 25
Cable (mm2)10 10 4 4 4 4
Fuse,fast(A) 63 63 35 35 25 35
Cable (mm2)16 16 6 6 6 6
Mains cable rating in accordance with Swedish regulations.
4.2 Wiring instructions
DTB 250 is wired up for 400 V on
delivery, unless stated otherwise. If
any other voltage is used the
transformer must be reconnected as
showninfig.1.
Instructions are given alongside the
terminal block.
GB

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5 OPERATION
SPower switch Q01 for switching power on and off. Indicator lamp lights up and
fanstartsinposition”1”.
SIndicator lamp HL1: indicates that power is on.
SIndicator lamp HL2: indicates that thermal cut--out has tripped.
SPotentiometer RP01: for adjusting welding current in range 5--250A.
SSelector switch SA4: for selecting welding method (TIG or manual metal arc
welding AC or DC).
SPotentiometer RP04: for adjusting slope--up time 0.5--10 s, during which current
is gradually increased from the minimum current to the set current.
SPotentiometer RP03: for adjusting slope--down time 0.5--10 s, during which
current is gradually decreased from the set current to the minimum current.
SPotentiometer RP02: for adjusting the gas post--flow 0.5--30 s, i.e. the time the
gas continues to flow after the arc has died.
SSelector switch SA2: for choosing between HF start or touch start.
SSelector switch SA1: for choosing between local or remote control.
Local setting: welding is controlled by power source settings.
Remote setting: welding is controlled by pulse unit or remote unit settings.
SRemote socket XS1: for connecting remote unit or pulse unit.
SSelector switch SA3: for 2 stroke/4 stroke.
2 stroke: arc is struck when the torch switch is depressed and extinguished when the
switch is released.
4 stroke: there is no need to keep the torch switch depressed during the welding se-
quence. Press and release the switch to strike the arc. Press and release the switch
again to extinguish the arc.
STIG connection XS2 in quick connector for TIG torch, gas and controls.
SOKC connector XS3. XS4 for return cable and electrode cable.
SPotentiometer RP05 for balancing square wave output during AC welding.
In most situations the balance control can be set to the midway position, so that
the negative and positive half cycles have the same duration. If the knob is
turned clockwise it increases the oxide removal effect of the arc. If it is turned
anticlockwise it reduces the load on the electrode.
GB

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bt10d12e
a-- Option for connecting digital or analogue voltmeter and ammeter.
b-- RP01: Current setting
MMA (A) 20--250
TIG (A) 5--250
c-- RP05: Balance control 40--60%.
d-- Q01: Power switch and lamp, HL1: The lamp light up and the fan starts at
setting ”1”.
e-- HL2: Indicates that thermal cut--out has tripped.
f-- RP03: Choice of slope--down time 0.5--10 sec.
g-- RP04: Choice of slope--up time 0.5--10 sec.
h-- SA3: Switch for selecting 2 or 4 stroke operation.
i-- SA2: Switch for selecting HF on or off.
j-- RP02: Selection of gas post--flow time 0.5--30 sec.
k-- SA4: Switch for selecting welding method and current type.
Following combinations available:
--MMA DC
--MMA AC
-- T I G D C
-- T I G A C
l-- SA1: Switch for selecting remote or local control of welding current.
m-- XS1: Socket for remote control or pulse unit.
n-- XS2: Central connector intended for TIG torch, providing current supply, gas and
switch in single unit.
o-- XS3: Socket for electrode holder.
p-- XS4: Socket for return cable.
bt10d
0
0
2
GB

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5.1 TIG welding with DC
1. Check that the TIG torch, gas hose and return cable are properly connected.
2. Check that a correctly ground thoriated tungsten electrode is fitted to the torch.
3. Use the correct gas and adjust the gas flow to 5--10 l/min.
4. Set the polarity switch SA4 to ”TIG--DC”
5. Set the power switch Q01 to setting ”1” and make sure the flow of cooling air is
not obstructed.
6. Select the start method, HF or tough start.
7. Select local or remote current control using switch SA1.
8. Set the desired current (RP01), slope--up and slope--down times (RP04 and
RP03) and gas post--flow time (RP02).
9. The power source is now ready for welding.
5.2 TIG welding with AC
1. Check that the TIG torch, gas hose and return cable are properly connected.
2. Check that a tungsten or zirconium electrode is fitted to the torch.
3. Use the correct gas and adjust the gas flow to 5--10 l/min.
4. Set the polarity switch SA4 to ”TIG--AC”.
5. Set the power switch Q01 to setting ”1” and make sure the flow of cooling air is
not obstructed.
6. Set switch SA2 to the HF setting.
7. Select local or remote current control using switch SA1.
8. Set the desired current (RP01), slope--up and slope--down times (RP04 and
RP03) and gas post--flow time (RP02).
9. Adjusting the balance control.
In most situations the balance control can be set to the midway position, so that
the negative and positive half cycles have the same duration. If the knob is
turned clockwise it increases the oxide removal effect of the arc. If it is turned
anticlockwise it reduces the load on the electrode. The setting of the balance
control should be optimised for each individual welding situation.
10. The power source is now ready for welding.
GB

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bt10d12e
5.3 MMA welding with AC or DC
1. Check that the electrode and return cable are properly connected.
2. Check that the correct electrode is being used for the current type.
3. Set the polarity switch SA4 to the ”correct” setting to suit the type of electrode
that is being used.
4. Set the power switch Q01 to setting ”1” and make sure the flow of cooling air is
not obstructed.
5. Select local or remote current control using switch SA1.
6. Set the chosen welding current using potentiometer (RP01).
7. The power source is now ready for welding.
6 MAINTENANCE
DTB 250 requires very little maintenance. Normally all that is required is to blow the
power source clean with dry compressed air at reduced pressure once a year. If the
power source is used in dusty or dirty premises it should be cleaned more often.
7 ORDERING OF SPARE PARTS
When ordering spare parts please state the machine model, designation, serial
number and the name and number of the spare part as shown in the list of spare
parts.
This will simplify dispatch and ensure correct delivery.
GB