Murex Tradesarc 150 User manual

GB
Valid for serial no. 827--xxx--xxxx0460 813 074 090605
Tradesarc 150
Instruction manual and
spare parts list

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Rights reserved to alter specifications without notice.
1 DIRECTIVE 3........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 5...................................................
4 TECHNICAL DATA 5.................................................
5 INSTALLATION 6....................................................
5.1 Location 6..................................................................
5.2 Mains power supply 6........................................................
6 OPERATION 7.......................................................
6.1 PFC -- Power factor correction 7..............................................
6.2 Connections and control devices 7............................................
6.3 Control panel 7.............................................................
6.4 Connection of welding and return cable 8.......................................
6.5 Overheating protection 8.....................................................
6.6 MMA welding 8.............................................................
6.7 TIG welding 8...............................................................
7 MAINTENANCE 9....................................................
7.1 Power source 9.............................................................
7.2 Welding torch 9.............................................................
8 FAULT--TRACING 10..................................................
9 ORDERING SPARE PARTS 10..........................................
10 DISMANTLING AND SCRAPPING 10...................................
DIAGRAM 12............................................................
SPARE PARTS LIST 15...................................................
ACCESSORIES 21.......................................................

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1DIRECTIVE
DECLARATION OF CONFORMITY
Murex Welding Products Ltd, EN8 7TF England, gives its unreserved guarantee that welding power
source Tradesarc 150 from serial number 827 (2008 w 27) are constructed and tested in compliance
with the standard EN 60974--1 and EN 60974--10 (Class A) in accordance with the requirements of
directive (2006/95/EC) and (2004/108/EEC).
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Kent Eimbrodt
Global Director
Equipment and Automation
On behalf of Murex Welding Products Ltd.
Laxå 2008--08--28
Manufactured by ESAB AB, Welding Equipment
SE--695 81 Laxå Sweden
2SAFETY
Users of 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 recommendations
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 precausions 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!
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Read and understand the instruction manual before
installing or operating.
CAUTION!
This product is solely intended for arc welding.
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.
MUREX can provide you with all necessary welding protection and accessories.
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3 INTRODUCTION
Tradesarc 150 is a welding current power source intended for use with coated
electrodes (MMA welding) and TIG welding.
Tradesarc 150 is supplied with 3 m of mains cable and an instruction manual.
Accessories for the product can be found on page 21.
4 TECHNICAL DATA
Tradesarc 150
Mains voltage 230 V, 1 μ50/60 Hz
Primary current
Imax 22 A
Mains supply Zmax 0.35 ohm
No--load power 30 W
Voltage/current range 8 A /20 V -- 150 A /26 V
Permissible load
25% duty cycle
60% duty cycle
100% duty cycle
150 A / 26.0 V
100 A / 24.0 V
90 A / 23.6 V
Power factor at maximum current 0.99
Efficiency at maximum current 80%
Open--circuit voltage 58 -- 72 V
Operating temperature -- 10˚C-- +40˚C
Transportation temperature -- 20˚C-- +55˚C
Constant sound pressure at no load <70dB
Dimensions, l x b x h 418 x 188 x 208 mm
Weight 7.9
Enclosure class IP 23
Application class
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. The duty cycle is valid for 40˚C.
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.
Mains supply, Zmax
Maximum permissible line impedance of the network in accordance with IEC 61000--3--11.
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5 INSTALLATION
The installation must be executed by a professional.
Note!
Mains supply requirements
High power equipment may, due to the primary current drawn from the mains supply, influence the
power quality of the grid. Therefore connection restrictions or requirements regarding the
maximum permissible mains impedance or the required minimum supply capacity at the interface
point to the public grid may apply for some types of equipment (see technical data). In this case it
is the responsibility of the installer or user of the equipment to ensure, by consultation with the
distrubution network operator if necessary, that the equipment may be connected.
5.1 Location
Place the power source so that its cooling air inlets and outlets are not obstructed.
5.2 Mains power supply
Check that the welding power source is connected to the correct voltage and that the
correct fuse size is used.
The standards for the country in question must be complied with as regards the
mains cable area.
A protective earth connection must be made in
accordance with regulations
Rating plate with supply connection data
5.2.1 Recommended fuse sizes and minimum cable area
Tradesarc 150
Mains voltage 230 V ¦10 %, 1--phase
Mains frequency 50--60 Hz
Mains cable, area 3G2.5 mm2
Phase current I1eff 11 A
Welding cable, area 16 mm2
Fuse
anti--surge
type C MCB 16 A
13 A
*) NOTE! The installed plug is approved for max. 16A.
NOTE! The cable area and fuse rating above comply with Swedish regulations. Use the welding
power source in accordance with the relevant national regulations.
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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 PFC -- Power factor correction
The Tradesarc is 230 V single--phase power sources equipped with a PFC circuit
making it possible to use the full range of the machine on a 16 A fuse. The PFC also
protects the machines against fluctuating mains voltage and makes it safer to use
with a generator. Tradesarc 150 can operate with extra long mains cables, over 100
m, giving you a very larger working radius.
6.2 Connections and control devices
1Connection (+)
MMA: for return cable or welding cable
TIG: for return cable
4Toggle switch for mains power supply 0 / 1
2Control panel, see under 6.3 5Mains cable
3Connection (--)
MMA: connection for return cable
TIG: connection for Tig torch
6.3 Control panel
SKnob for setting the current
SMains voltage LED (green)
SThermal overload trip indicator
(yellow)
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6.4 Connection of welding and return cable
The power source has two outputs, a positive (+) terminal and a negative (--)
terminal, for connecting welding and return cables. The output to which the welding
cable is connected depends on the type of electrode used. The connecting polarity is
stated on the electrode packaging.
Connect the return cable to the other output on the power source. Secure the return
cable’s contact clamp to the work piece and ensure that there is good contact
between the work piece and the output for the return cable on the power source.
6.5 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.
6.6 MMA welding
Tradesarc 150 gives direct current, and you can weld most metals to alloy and non--
alloy steel, stainless steel and cast iron. Tradesarc 150 allows you to weld most coated
electrodes from ∅1.6 to ∅3.25.
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 immedi-
ately 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, then raise it so
as to give an appropriate arc length (approx. 2 mm). If the arc
is too long, it will crackle and spit before finally going out com-
pletely.
If you are working on a welding bench, check before attempting
to strike the arc that residual waste metal, pieces of electrode
or other objects on the bench do not insulate the part to be
welded.
Once the arc has been struck, move the electrode from left to
right. The electrode must be at an angle of 60˚to the metal in
relation to the direction of welding.
When you want to weld wide beads, or when you want the weld
to be so thick that you have to weld in a number of layers, how-
ever, you have to use lateral movements.
6.7 TIG welding
TIG welding melts the metal of the workpiece, using an arc struck from a tungsten
electrode, which does not itself melt. The weld pool and the electrode are protected
by shielding gas.
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TIG welding is particularly useful where high quality is demanded and for welding
thin plate. Tradesarc 150 also has good characteristics for TIG welding.
In order to TIG weld, Tradesarc 150 must be equipped with:
Sa TIG torch with gas valve
Sa welding gas cylinder (a suitable welding gas)
Sa welding gas regulator (suitable gas regulator)
Stungsten electrode
Ssuitable auxiliary material, if necessary.
TIG scrape start
To scrape start lightly scrape the tungsten
electrode against the workpiece to create an arc.
7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
CAUTION!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any faults.
WARNING!
The mains supply must be disconnected before cleaning!
7.1 Power source
Check regularly that the welding power source is not clogged with dirt.
How often and which cleaning methods apply depend on:
Sthe welding process
Sarc times
Splacement
Sthe surrounding environment.
It is normally sufficient to blow down the power source with dry compressed air
(reduced pressure) once a year.
Clogged or blocked air inlets and outlets otherwise result in overheating.
7.2 Welding torch
The welding torch’s wear parts should be cleaned and replaced at regular intervals in
order to achieve trouble--free welding.
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8 FAULT--TRACING
Try these recommended checks and inspections before sending for an authorised
service technician.
Type of fault Corrective action
No arc. SCheck that the mains power supply switch is turned on.
SCheck that the welding current supply and return cables are
correctly connected.
SCheck that the correct current value is set.
SCheck the mains power supply.
The welding current is
interrupted during welding. SCheck to see whether the thermal cut--outs have tripped.
SCheck the mains power supply fuses.
The thermal cut--out trips
frequently. SMake sure that you are not exceeding the rated data for the welding power source (i.e. that the unit is not being
overloaded).
Poor welding performance. SCheck that the welding current supply and return cables are
correctly connected.
SCheck that the correct current value is set.
SCheck that the correct electrodes are being used.
SCheck the gas flow.
9 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorized serviceman.
Use only original spare and wear parts.
Tradesarc 150 is designed and tested in accordance with the international and Europe-
an standard IEC/EN 60974--1. EN 60974--10 It is the obligation of the service unit which
has carried out the service or repair work to make sure that the product still conforms
to the said standard.
10 DISMANTLING AND SCRAPPING
Weldingequipmentprimarilyconsistsofsteel,plasticandnon--ferrousmetals,andmust
be handled according to local environmental regulations.
Coolant must also be handled according to local environmental regulations.
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human
health!
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Diagram
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Tradesarc 150
Edition 090605
Spare parts list
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Valid for serial no. 827--xxx--xxxx
Ordering number
0460 441 880 Tradesarc 150, for 230 V 50/60 Hz with MMA--kit
Spare parts are to be ordered through the nearest MUREX agency. Kindly indicate type of unit, serial
number, denominations and ordering numbers according to the spare parts list.
Maintenance and repair work should be performed by an experienced person, and electrical work only
by a trained electrician. Use only recommended spare parts.

Tradesarc 150
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C = component designation in the circuit diagram
Item Qty Ordering no. Denomination Notes C
AA1 10193 317 001 Switch Included in item AA50 2QF1
AA2 1-- Cord set Included in item AA50
AA3 10460 140 001 Rear panel
AA4 10460 143 001 Cover
AA5 10460 476 880 MMC Module A31 Including AA6 and AA7
AA6 10460 600 328 Knob Included in AA5
AA7 1-- Ribbon cable with connectors 34 pole, included in AA5 1XS1, 1XS2
AA8 10460 479 004 Side panel right
AA9 10460 479 003 Side panel left
AA10 0194 179 327 Screw MRT ground cutter, M5x12
AA11 1-- Front panel Included in item AA51
AA13 10460 690 001 Sticker Tradesarc 150
AA14 50366 588 001 Nut
AA15 60469 381 002 Fast lock nut M5
AA16 10460 427 001 Bar plus
AA17 10460 152 981 Cable set course
AA18 20160 362 025 Connector OKC 50 Included in item AA51 XS1, XS2
AA19 20366 247 001 Nut
AA20 20366 306 003 Spring washer Ø21/15x1
AA21 20468 497 001 Holder
AA22 10460 265 001 Strap
SPARE PARTS SETS
Item Ordering no. Denomination Notes
AA50 0460 601 881 Mains module Includes items: AA1 switch, AA2 mains cable with plug, cable clamp and one ferrite
rings 2L2.
AA51 0460 379 894 Front complete Includes items: AA11, AA18, AA19, AA20
When replacing “front complete” also item AA5, MMC module, must be replaced.

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C = component designation in the circuit diagram
Item Qty Ordering no. Denomination Notes C
AB1 10487 261 880 Power supply/control board 20AP1
AB2 10193 700 702 Ribbon cable with connectors 10 pole 20XS3, 20XS4
AB3 10468 940 005 Thermal switch Socket connector 15XS5 included 15ST2
AB4 1Diode module See item AB50 15D1
AB5 10459 177 001 Inductor 15L1
AB6 10459 355 881 Transformer Includes: main transformer, socket 15XS4,
socket 15XS6, thermal switch 15ST1 15TM1
AB7 10460 117 001 Inductor PFC 15L2
AB8 10194 158 003 Capacitor 1000 uF 450 V DC 15C1
AB9 0487 060 880 Secondary board 15AP2
AB10 1Circuit board See item AB51 15AP1
AB11 1Semiconductor module See item AB51
AB12 10468 030 880 Shunt 15RS1
AB13 10459 194 001 Busbar
AB14 10467 801 002 Fan 24 V DC; with cables and socket 15XS3 15EV1
SPARE PARTS SETS
Item Qty Ordering no. Denomination Notes
AB50 10459 385 880 Diode module kit Includes: item AB4 diode module, screws (type A and B),
thermal compound and roller.
AB51 10459 384 887 Power board kit Includes: item AB10 power board, item AB11 semiconductor
module, screws (type A and B), thermal compound and roller.
-- 0458 910 002 Roller handle For the roller in the spare parts sets above
-- 0192 058 101 Thermal compound

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