Murex Tradestig 200-1 User manual

GB
Valid for serial no. 517--xxx--xxxx0459 758 074 050526
Tradestig 150- 1
Tradestig 200- 1
Instruction manual and
spare parts list

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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 5...................................................
3.1 Equipment 5................................................................
4 TECHNICAL DATA 5.................................................
5 INSTALLATION 6....................................................
5.1 Placing 6...................................................................
5.2 Rating plate 6...............................................................
5.3 Mains power supply 6........................................................
6 OPERATION 7.......................................................
6.1 Connections and control devices 7............................................
6.2 Control panel 8.............................................................
6.3 Overheating protection 8.....................................................
7 WELDING 9.........................................................
7.1 TIG welding 9...............................................................
7.2 MMA welding 11.............................................................
8 MAINTENANCE 11....................................................
9 FAULT TRACING 12...................................................
9.1 Fault codes 12...............................................................
10 ORDERING SPARE PARTS 12..........................................
DIAGRAM 14............................................................
SPARE PARTS LIST 16...................................................
ACCESSORIES 23.......................................................

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1DIRECTIVE
DECLARATION OF CONFORMITY
Murex Welding Products Ltd, EN8 7TF England, gives its unreserved guarantee that welding power
source Tradestig 150--1 and Tradestig 200--1 from serial number 517 complies with standards
EN 60974--1/--3, in accordance with the requirements of directive (72/23/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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Henry Selenius
Managing Director
ESAB AB, Welding Equipment
SE--695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
On behalf of Murex Welding Products Ltd.
Laxå 2005--05--25
Manufactured by ESAB Welding Equipment AB.
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 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!
WARNING!
Read and understand the instruction manual before installing
or operating.
We can provide you with all necessary welding protection and accessories.
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
The Tradestig 150--1, Tradestig 200--1 are a welding current power sources
intended for use with coated electrodes (MMA welding) and TIG welding.
3.1 Equipment
The Tradestig is supplied with a mains cable and an instruction manual.
Accessories for the product can be found on page 23.
4 TECHNICAL DATA
Tradestig 150--1 Tradestig 200--1
Mains voltage 230V, 1∼50/60 Hz 230V, 1∼50/60 Hz
Fuse (delayed--action) 16 A 20 A
Primary current Imax 36 A 36 A
Primary current Ieff 21 A 21 A
Voltage/current range
(TIG)
(MMA) 3 A / 10 V --150 A / 16 V
4 A / 20 V --150 A / 26 V 3 A / 10 V -- 200 A / 18 V 4 A / 20 V -- 150 A / 27 V
Maximum permissible load at TIG
25% duty cycle
35% duty cycle
60% duty cycle
100% duty cycle
150 A / 16 V
120 A / 15 V
95 A / 14 V
200 A / 18 V
180 A / 17 V
140 A / 15,5 V
110A/14,5V
Maximum permissible load at MMA
25% duty cycle
35% duty cycle
60% duty cycle
100% duty cycle
150 A / 26 V
140 A / 25,5 V
110A/24,5V
90 A / 23,5 V
150 A / 26 V
140 A / 25,5 V
110A/24,5V
90 A / 23,5 V
Power factor at maximum current 0,62 0,62
Efficiency at maximum current 77 % 79 %
Open--circuit voltage 71 -- 78 V 71 -- 78 V
Operating temperature -- 1 0 ˚C--+40˚C-- 1 0 ˚C--+40˚C
Constant A--weighed sound pressure <70 db <70 db
Dimensions, l x b x h 380 x 180 x 300 mm 380 x 180 x 300 mm
Weight 9kg 9kg
Enclosure class IP 23C IP 23C
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.
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.
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4.1 Parameter setting
Settings Setting range In steps of: Default value
Welding method TIG or MMA -- TIG
2/4--stroke 2strokeor4stroke -- 2--stroke
HF / Lift ArctHF or LiftArct-- HF
Slope down time 0--10 s 0.1 s 1.0 s
Gas post--flow 0--25 s 0.1 s 2.0 s
Current TIG Tradestig 150--1 3 -- 150 A 1A 100 A
Current TIG Tradestig 200--1 3 -- 200 A 1A 100 A
Current MMA Tradestig 150--1 4 -- 150 A 2A 60 A
Current MMA Tradestig 200--1 4 -- 150 A 2A 100 A
5 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.
5.1 Placing
Place the power source so that its cooling air inlets and outlets are not obstructed.
5.2 Rating plate
The rating plate is located on the rear side of the power source.
5.3 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 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.
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5.3.1 Recommended fuse sizes and minimum cable areas
Tradestig 150--1 Tradestig 200--1
Mains voltage 230 V ¦10 %, 1--phase 230 V ¦10 %, 1--fas
Mains frequency 50--60 Hz 50--60 Hz
Fuse (delayed--action)
85A 35% duty cycle MMA
120A 20% duty cycle MMA
150A 25% duty cycle MMA
10 A
16 A
20 A*)
10 A
16 A
20 A *)
Mains cable, area 3x2.5mm
23x2,5mm 2
Welding cable, area MMA 16 mm216 mm2
Welding cable, area TIG 16 mm225 mm2
*) NOTE! The mains plug is approved for maximum 16A.
6OPERATION
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 Connections and control devices
Make sure that the welding power source is connected to the correct supply voltage
and that it is protected by the correct fuse rating.
1. Mains switch
2. Mains cable
3. Connection for gas from gas bottle
4. Connection for the TIG torch switch
5. Connection for gas to the TIG torch
6. TIG torch connection (--)
7. MMA: return cable connection (--)
8. TIG: return cable connection (+)
MMA: welding cable connection (+)
9. Control panel (see 6.2)
Note! 7 and 8are used for welding
current supply and return cable
connection during MMA welding
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6.2 Control panel
The power source checks the LEDs and all segments in the display when main
switch is turned on. The machine type and program version are also displayed.
The control panel comprises a display, setting knob, LEDs and pushbuttons. Using
the pushbuttons, it is possible to move between the various functions. The selected
function is indicated by the relevant LED lighting up.
1. Indicating lamp, mains
power supply On.
2. Display.
3. Indicating lamp, overheating.
4. Knob for setting data.
5. Selection of TIG or MMA
welding mode.
6. Selection of TIG HF start or
TIG LiftArc start .
7. Selection of TIG 2--stroke or TIG 4--stroke control mode.
8. Slope--down time.
9. Gas post--flow time.
6.3 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.
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7 WELDING
7.1 TIG welding
During TIG welding, the return cable must be connected to (+) and the TIG torch to
(--). If they are connected in reverse, the tungsten electrode will melt.
7.1.1 2--stroke
Gas pre--flow Slope
up Slope down Gas post--flow
Functions when using 2--stroke control of the welding torch.
In the 2--stroke control mode, pressing the trigger switch starts gas pre--flow (0.5 sec)
and strikes the arc (1). The current rises to the set value (as controlled by the slope up
function, if in operation). Releasing the trigger switch (2) reduces the current (or starts
slope down if in operation) and extinguishes the arc. Gas post--flow follows if it is in
operation.
7.1.2 4--stroke
Gas pre--flow Slope
up Slope down Gas post--flow
Functions when using 4--stroke control of the welding torch.
In the 4--stroke control mode, pressing the trigger switch starts gas pre--flow (0.5 sec)
(1). At the end of the gas pre--flow time, the current rises to the pilot level (a few
ampere), and the arc is struck. Releasing the trigger switch (2) increases the current to
the set value (with slope up, if in use). At the end of welding, the welder presses the
trigger switch again (3), which reduces the current to pilot level again (with slope down,
if in use). Releasing the switch again (4) extinguishes the arc and starts gas post--flow.
7.1.3 HF
The HF function strikes the arc by means of a spark from the tungsten electrode to
the workpiece as the electrode is brought closer to the workpiece.
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7.1.4 LiftArct
The LiftArctfunction strikes the arc when the electrode is brought into contact with
the workpiece and then lifted away from it.
Striking the arc with the Lift Arc t function. Step 1: the electrode is touched on to the workpiece.
Step 2: the trigger switch is pressed, and a low current starts to flow. Step 3: the welder lifts the torch
from the workpiece: the arc strikes, and the current rises automatically to the set value.
7.1.5 Gas post--flow
This controls the time during which shielding gas flows after the arc is extinguished.
7.1.6 Slope down
TIG welding uses slope down, by which the current falls ’slowly’ over a controlled
time, to avoid craters and/or cracks when a weld is finished.
Current
A higher current produces a wider weld pool, with better penetration into the
workpiece.
The current set value can be changed irrespective of which menu is displayed. This
value is displayed in the main menu only.
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7.2 MMA welding
The Tradestig gives direct current, and you can weld most metals to alloy and non--alloy
steel, stainless steel and cast iron.
The Tradestig 150--1 allows you to weld most coated electrodes from ∅1.6 to ∅3.25.
The Tradestig 200--1 allows you to weld most coated electrodes from ∅1.6 to ∅4.0
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 im-
mediately 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 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.
8 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Note!
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.
The Tradestig requires little maintenance. In normal cases, it is sufficient to blow it
clean using dry compressed air once a year, but this should be done more often if it
is set up in a dusty, dirty area.
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9 FAULT TRACING
Try these recommended checks and inspections before sending for an authorised
service technician.
Type of fault 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.
The thermal overload trips
operate frequently.
SCheck whether the thermal overload trips have operated
(indicated by the yellow lamp on the front panel).
SCheck the main power supply fuses.
The thermal overload trip
operates 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.
9.1 Fault codes
The Tradestig comes with built--in fault monitoring. If a fault occurs, a code is shown in
the display.
If any of these fault codes (Exx) reappears once the unit has been restarted, the
welding power source should be sent to an authorised ESAB service workshop for
repair.
10 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorized serviceman.
Use only original spare and wear parts.
Tradestig 150--1 and Tradestig 200--1 are designed and tested in accordance with the
international and European standards EN 60974--1/--3 and EN 50199. It is the obligation
of the service untit which has carried out the service or repair work to make sure that
the product still conforms to the said standard.
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Diagram Tradestig 150- 1, Tradestig 200- 1
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bt29 diagram
Tradestig 150--1, Tradestig 200--1

Tradestig 150- 1, Tradestig 200- 1
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bt29 diagram

Tradestig 150- 1, Tradestig 200- 1
Edition 050526
Spare parts list
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0569 758 074
Valid for serial no. 517--xxx--xxxx
Ordering number
0459 760 881 Tradestig 150--1 for 230 V mains voltage
0459 760 883 Tradestig 200--1 for 230 V mains voltage
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.

Tradestig 150- 1, Tradestig 200- 1
Edition 050526
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bt26saa1
C = component designation in the circuit diagram
Item Qty Ordering no. Denomination Notes C
AA1 10459 654 001 Handle
2 Screw M8x50
AA3 10459 173 002 Cover
AA4 4 Screw M5x12
AA5 1 Screw M5x16 Included in item AB51, see page 18.

Tradestig 150- 1, Tradestig 200- 1
Edition 050526
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C = component designation in the circuit diagram
Item Qty Ordering no. Denomination Notes C
AB1 10193 317 001 Switch Included in item AB50 2QF1
AB2 1Cord set Included in item AB50
AB3 Screw Included in item AB51 and AB53
AB4 10459 174 001 Rear panel
AB5 10487 018 880 Display board Included in item AB51 1AP2
AB6 1Front panel Included in item AB51 and AB53
AB7 1Control Panel Included in item AB51 1AP1
AB8 10321 475 893 Knob Included in item AB51
AB9 50366 588 001 Nut
AB10 Spacer Included in item AB51
AB11 30366 306 883 Connector OKC 25 Included in item AB51 29XS1, 29XS2,
29XS3
AB12 3 Screw M5x12 Torx. Included in item AB51
AB13 1Cable shoe Included in item AD4, see page 22
AB14 10459 194 003 Busbar, positive
AB15 10459 194 002 Busbar, negative
AB16 10194 130 120 Nut Included in item AB51
AB17 10459 269 001 Gas connection Included in item AB51
AB18 1Socket 2 pole. Included in item AB52 29XS4
SPARE PARTS SETS
Item Ordering no. Denomination Notes
AB50 0459 183 880 Mains module Includes items: AB1 switch, AB2 mains cable with plug, cable clamp and two
ferrite rings 2L1.
AB51 0459 386 886 Front complete, TIG Includes items: AA5, AB3, AB5, AB6, AB7, AB8, AB10, AB11, AB12, AB16,
AB17, AB18
AB52 0459 280 891 Cable set 2 pole socket 29XS4, 5 pole socket 29XS6, 1 pole socket 29XS8 and the wires
between them.

Tradestig 150- 1, Tradestig 200- 1
Edition 050526
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bt26sab1

Tradestig 150- 1, Tradestig 200- 1
Edition 050526
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C = component designation in the circuit diagram
Item Qty
150
Qty
200
Ordering no. Denomination Notes C
AC1 1 1 0487 064 880 Power supply board 2AP1
AC2 1 1 0459 280 880 Cable set Including wires 1501, 1502 and their
sockets 15XS1, 15XS2, 15XS7, 15XS8
1 1 0193 700 702 Cable set 20XS3, 20XS4
1 1 0459 280 881 Cable set 20XS1, 20XS2,
20XS5
AC3 1 1 0459 390 880 Control board kit Before mounting the board, the strapping
must be set up to fit CaddyTig 150 or
CaddyTig 200. See the service manual.
20AP1
AC4 10468 940 004 Thermal switch Socket connector 15XS5 included 15ST2
10468 940 005 Thermal switch Socket connector 15XS5 included 15ST2
AC5 1 1 Diode module See item AC50 15D1
AC6 1 1 0459 177 001 Inductor 15L1
AC7 1 1 0459 355 880 Transformer Includes: main transformer, socket 15XS4,
socket 15XS6, thermal switch 15ST1 15TM1
AC8 0487 060 880 Secondary board 15AP2
AC9 1 1 0459 273 001 Earth bracket
AC10 10194 158 001 Capacitor 1000 uF 400 V DC 15C1
10194 158 002 Capacitor 2000 uF 400 V DC 15C1
AC11 10467 801 002 Fan 24 V DC; With cables and socket 15XS3 15EV1
AC11 10458 065 002 Fan 24 V DC; With cables and socket 15XS3 15EV1
AC12 1 1 Circuit board See item AC51 15AP1
AC13 1 1 Semiconductor module See item AC51
AC14 1 1 0468 030 880 Shunt 15RS1
AC15 1 1 0459 194 001 Busbar
SPARE PARTS SETS
Item Qty
150
Qty
200
Ordering no. Denomination Notes
AC50 10459 385 880 Diode module kit Includes: item AC5 diode module, screws (type A and B), thermal
compound and roller.
10459 385 881 Diode module kit Includes: item AC5 diode module, screws (type A and B), thermal
compound and roller.
AC51 10459 384 880 Power board kit Includes: item AC12 power board, item AC13 semiconductor
module, screws (type A and B), thermal compound and roller.
10459 384 881 Power board kit Includes: item AC12 power board, item AC13 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