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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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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