Aristotig 200
Aristotig 200 AC/DC
DTE 200
Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung
Manuel d’instructions
0458 234 001
021214
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções
Ïäçãßåò ÷ñÞóåùò
Instrukcja obs³ugi
Valid for serial no. 914, 246
ENGLISH
1 DIRECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
60
61
3.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
4 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
63
5.1 Location and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
6.1
6.2
6.3
6.4
6.5
6.6
6.7
Controls and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protection against overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MMA welding (Hand welding electrodes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIG welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forced disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
65
65
65
68
69
71
7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
7.1 Check--up and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
8 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
TOCe
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1
DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guarantee that welding power source DTE 200 from serial number 914 complies with standard 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 requirements of directive (89/336/EEC) and addendum (93/68/EEC).
-------------------------------------------------------------------------------------------------------------------------------------Laxå 1999--03--31
Anders Birgersson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN
2
Tel: + 46 584 81000
Fax: + 46 584 411924
SAFETY
Users of ESAB 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:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2.
The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3.
The workplace must:
S be suitable for the purpose
S be free from draughts
4.
Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5.
General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
S
Install and earth the welding unit in accordance with applicable standards.
S
Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S
Insulate yourself from earth and the workpiece.
S
Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S
Keep your head out of the fumes.
S
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.
S
Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S
Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S
Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S
Protect your ears. Use earmuffs or other hearing protection.
S
Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
3
INTRODUCTION
DTE 200 is a compact welding power source for two different welding methods.
It can be used for:
welding with tungsten electrodes (TIG), using direct or alternating current.
manual metal arc welding with coated electrodes (MMA), using direct or
alternating current.
DTE 200 is available in two designs:
S
S
S with OKC connection for the TIG torch
S with central connection for the TIG torch
Note: Remove the TIG torch when using the MMA method.
When TIG welding, remove the electrode holder.
ESAB’s accessories for the product can be found on page 196.
3.1
Equipment
DTE 200 is delivered with:
S
S
S
S
Mains cable (3 m)
Return cable (5 m)
Gas hose
Hose clamps
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4
TECHNICAL DATA
DTE 200
Permissible load at
35% duty cycle (MMA)
60% duty cycle (MMA)
100% duty cycle (MMA)
35% duty cycle (TIG)
60% duty cycle (TIG)
100% duty cycle (TIG)
170 A / 27 V
130 A / 25 V
100 A / 24 V
200 A / 18 V
150 A / 16 V
120 A / 15 V
Setting range, TIG
5--200 A, DC
5*--200 A, AC
Setting range, MMA
5--200 A
Slope--up
0 -- 10 s
Slope--down
0 -- 10 s
Gas preflow, adjustable on the circuit board
0 -- 5 s
Gas postflow
3 -- 30 s
Open circuit voltage
70 -- 90 V DC
No--load power, MMA
115 W
No--load power, TIG
60 W
Useful power, P (at max. current MMA)
6,2 kW
Apparent power, S (at max. current MMA)
6,4 kVA
Power factor at max. current, MMA
0,95
Efficiency at max. current, MMA
73%
Mains voltage
400 V
Mains frequency
50 -- 60 Hz
Welding cable, sectional area
35 mm2
Fuse, slow--acting
10 A
Mains cable, sectional area
4 x 2,5 mm2
Dimensions l x w x h
510 x 310 x 555 mm
Weight
45 kg
+/-- 10%
3~
Application class
IP 23
Enclosure class
*) The minimum current during AC welding depends on the alloy used for the aluminium plates and
their surface cleanliness.
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a certain load without overloading.
Application class
The symbol
indicates that the power source is designed for use in areas with increased
electrical hazard.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP 23 is designed for indoor and outdoor use.
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5
INSTALLATION
The installation must be executed by a professional.
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.
DTE 200 has mains voltage compensation, which means that +/-- 10% variation in
the supply voltage produces only +/-- 0.2% variation in the welding current.
To reduce the voltage drop resulting from the use of long welding cables, a cable
with a larger sectional area than the one indicated under Technical Data on page 62
can be used.
When the power source is started, the cooling fans work at a reduced rotation
speed, partly to reduce the amount of dirt that can be sucked in and partly to ensure
a lower noise level.
When the power source requires increased cooling, the fans work at a higher
rotation speed.
5.1
Location and connection
S
Place the welding power source so that the cooling air in-- and outlets remain
free.
S
Connect the shielding gas (see fig. on page 64).
S
Connect the TIG torch and the torch return cable, alternatively the welding and
return cable of the electrode holder (see fig. on page 64).
S
Make sure the welding power source is connected to the right mains voltage and
that it is properly fused. Connect to earth according to applicable regulations.
Rating plate with connection data is located on the rear of the welding power
source.
The machine is now ready for use.
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6
OPERATION
General safety regulations for the handling of the equipment can be found on
page 60. Read through before you start using the equipment!
6.1
Controls and connections
Central connection
A
Mains switch ON/OFF
H
Mains voltage ON, LED
B
Connection for remote control unit
J
Welding voltage ON, LED
C
Torch connector
L
Error / Overheating, LED
D
Connection for electrode holder (MMA)
M
Flow guard, LED
(Functions when the cooling unit is
connected)
E
OKC connection for TIG torch
N
Connection for shielding gas to the machine
F
Return cable connection
O
Control unit, digital display
G
Shielding gas connection
P
Central connection for TIG torch
N.B. The positions C and G are dropped when the central connection is used.
When the mains switching device is turned on, the diode (H) goes on.
When open circuit voltage is applied diode (J) goes on.
When an error occurs, for example overheating, diode (L) goes on.
When there is no water flow diode (M) goes on.
When there is a fault that can cause temporary high output voltage, the LED
switches off (J), (output voltage has been switched off). When idling for longer than
30 minutes, the output voltage is switched off and diode (J) goes out.
Restart by turning the switch (1) to TIG mode and then back to MMA mode.
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6.2
Remote control unit
For both the TIG and MMA methods the welding current can be adjusted by way of a
remote control unit. The welding power source registers automatically when a
remote control unit is connected.
If the remote control is to include the whole current range, the current must be set to
max. on the welding power source.
Max. value = The reference value set on the welding power source.
6.3
Protection against overheating
Three thermal cut--outs prevent the power source being overloaded as a result of too
high temperature. If this should happen, the welding current is interrupted and the
yellow diode (L) goes on. (See page 64.)
When the temperature has gone down, the welding current circuit is reclosed and
the diode goes out.
6.4
Control panel
1
Method selection switch
2
3
Ignition selection switch
Pulsing selection switch
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S
MMA welding (hand welding electrodes)
S
TIG, two--stroke (also for remote control)
S
TIG, four--stroke
S
TIG four--stroke with the possibility to shift between
two currents (shift function). See items 8 and 9 on
page 66 for setting of the two currents.
S
HF ignition
S
Lift--Arc ignition, see page 67.
S
Non--pulsed welding, d.c. and a.c.
S
Welding with square--wave pulsing; d.c. and a.c.
S
Welding with trapezi--form pulsing; d.c. and a.c.
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GB
4
Polarity selection switch
S
Alternating current
S
Square--wave alternating current
S
Direct current, negative electrode (normal in TIG
welding)
S
Direct current, positive electrode
S
Direct current, negative electrode, but with positive
electrode at the start (for example for 3.2 mm
electrodes, TIG welding).
5
Potentiometer for Hot Start
S
For setting and optimising the starting cycle with
regard to the electrode size.
TIG welding ( 10...500 ms )
MMA welding (100ms...2s)
6
Potentiometer for Arc--Force
S
For setting and optimising the Arc--Force function
(Anti-- Stick), for MMA welding only.
7
Potentiometer
S
For setting the slope--up time of the welding current
(0 to 10 seconds).
8
Potentiometer I1
S
For setting the non--pulsed welding current and the
current pulse when welding with pulsed current.
9
Potentiometer I2
S
For setting the background current for pulsed
welding and the lower current level when using the
shift function.
10 Potentiometer
S
For setting the welding current slope--down (0 to 10
seconds).
11
S
For setting the gas postflow time (3 to 30 seconds).
Potentiometer
12 Potentiometer for setting the frequency
This potentiometer has double functions:
S
For setting the pulse frequency between 0.3 and
300 Hz for pulsed welding with direct current.
For setting the a.c. frequency between 30 and 300
Hz for non--pulsed welding with alternating current.
N.B. When welding with pulsed alternating current,
the a.c. frequency is automatically set to 100 Hz!
The max. pulse frequency to be set is then 100 Hz!
S
13 Potentiometer for setting the balance
This potentiometer has double functions:
S
For setting the balance between positive and
negative half--wave when welding with alternating
current to optimise the cleaning or the penetration.
(Turning right =>increased penetration.)
For setting the time relation between the
background and the peak current when welding
with direct current.
(Turning right =>longer pulse current time.)
N.B. When welding with pulsed a.c. the time balance between the pulse current and the base current will automatically be 50/50%.
The relationship between positive and negative half-wave is adjusted in the same in the same way as non-pulsating AC welding.
S
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Position
= MMA
In this position the welding power source is prepared for welding with coated
electrodes. The HF unit and the Lift--Arc are disconnected, and the hot--start function
is activated in order to supply incresaed current at the start.
Position
= HF unit ON
When pressing the torch trigger the gas starts flowing, the HF unit goes on,
generating an electric spark between the electrode and the welding material, the gas
is ionised and an arc is produced. When the arc is stable, the HF unit will
automatically be disconnected.
Position
= Lift--Arc
By Lift--Arc is meant that you place the torch with the electrode on the spot where
you want to start the welding, press the torch trigger and lift up the torch. In doing so
an arc is produced.
The current slowly increases up to the set value during the set ”slope up” time.
When you want to finish welding, the contact is released and the current slowly
decreases to the set ”slope down” time.
Place the electrode against the workpiece.
Press in the torch trigger.
Tilt the torch a little, lift and an arc is produced.
To stop, release the torch trigger.
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Position
Two/four--stroke
Two--stroke means that the arc is struck when the torch trigger is pressed and
extinguished when it is released.
Four--stroke means that it is not necessary to keep the torch trigger pressed while
the welding is going on. The arc is struck by pressing an releasing the switch and is
extinguished by repeating the action.
Four--stroke 4--stroke with the possibility to switch between two currents (switching
function).
Through short activation of the burner contact, the switching function gives rise to
switching between two adjustable currents.
If the burner contact is kept pressed in, the current starts to slope down.
6.5
MMA welding (Hand welding electrodes)
6.5.1 Adjusting the control panel for MMA welding
S Connect the welding and return cable to the OKC terminals D and F.
S Set switch (1) to the position for hand welding electrodes.
The LED (J) indicates that open circuit voltage is available on the welding
terminals. (See also point 5.2.)
S Set the desired value for welding current using potentiometer (8).
It is also possible to use pulsed welding current. The settings are made in the
same way as for pulsed TIG welding.
S Potentiometer (5) is used for stepless setting of the Hot--Start function,
potentiometer (6) for stepless setting of the Arc--Force function, and thereby the
control dynamics.
S Depending on the electrode type to be used, direct current and polarity or one of
the alternating current alternatives can be selected by way of switch (4) without
shifting the welding cables.
The welding current can be set over a hand--operated remote control unit.
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6.6
TIG welding
In TIG welding the torch trigger has three different functions:
S
Two--stroke
S
Four--stroke
S
Four--stroke with the possibility to shift between two currents (shift function).
6.6.1
Adjusting the control panel for TIG welding
S
Connect the Tig burner and the earth lead into the OKC outputs E and F
(connect to outputs P and F when there is a central connection).
S
Set switch (1) to the desired position.
If a foot--operated remote control unit is to be used, set switch (1) to position
two--stroke.
NB. For direct current control over the foot--operated remote control unit, the
potentiometer (7) and (10) must be set to position 0.
A hand--operated remote control unit can be used for both two--stroke and
four--stroke to set the welding current.
S
Select the desired striking method using switch (2).
S
Adjust the welding current using potentiometer (8).
S
Select the desired type of pulsing using switch (3).
S
For the shift function/pulsing, adjust the lower current value using potentiometer
(9).
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6.6.2
Schematic pulsed welding sequence.
6
1. The gas preflow time is preset at 10 ms.
2. Hot start:
S
The start current is preset at 100 A.
S
The time is adjusted on the front panel: 20 -- 500 ms.
3. The start current is 10 A.
4. The slope--up time is adjusted on the front panel: 0 -- 10 s.
5. The pulse current is adjusted on the front panel: 5 -- 200 A.
6. The background current is adjusted on the front panel: 10 -- 90% of the pulse
current.
7. The slope--down time is adjusted on the front panel: 0 -- 10 s.
8. At termination, the current is pre--set to 5 A.
9. The gas postflow time is adjusted on the front panel: 3 -- 30 s.
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6.6.3
Setting direct and alternating current
Direct current:
S
Set switch (4) to the position for direct current with negative polarity.
If pulsing has been selected:
S
Set the pulse current value using potentiometer (8).
S
Set the background current in per cent of the pulse current value using
potentiometer (9).
S
Set the pulse frequency using potentiometer (12).
S
Set the time relation between pulse and background current using
potentiometer (13).
Alternating current:
Two different types of alternating current can be set over switch (4):
S
A sine--wave type, characterised by low noise and a soft arc. Effective when low
frequencies are used!
S
A square--wave type, characterised by a hard and stable arc, resulting in a
somewhat higher noise level.
The arc is always struck by way of direct current which is then automatically
switched over to alternating current.
Increased alternating current frequency gives a concentrated and stable arc, suitable
above all when a low amperage is used and when welding in extremely thin plate.
The displacement (balance) of the half--wave in positive direction leads to increased
cleaning, and in negative direction to increased penetration.
(Turn potentiometer (13) more to the right for increased penetration!)
6.7
Forced disconnection
If the torch trigger or the foot--operated remote control unit has been activated and
no arc has been generated, the open circuit voltage is automatically disconnected
after 2 seconds. The same applies in the event of an arc interruption.
This function protects from:
S
Uncontrolled arc strike
S
Material damage
S
Shielding gas drop--out
S
Accidents
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7
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.
7.1
Check--up and cleaning
Clean the welding power source once a year using
dry compressed air (reduced pressure). The dust
filter is to be checked up and cleaned regularly.
If the welding power source is used in a dusty and
dirty environment, the cleaning should be
performed more frequently.
For maximal service reliability it could be
advisable to let an authorised retailer service the
machine once a year.
bt07d109
8
ORDERING OF SPARE PARTS
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list.
This facilitates dispatch and ensures correct delivery.
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SVENSKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
DANSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
NORSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SUOMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
DEUTSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
FRANÇAIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
NEDERLANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ESPAÑOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
ITALIANO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
PORTUGUÊS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
ÅËËÇÍÉÊÁ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
POLSKI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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.
Zastrzegamy sobie prawo do wprowadzenia zmian.
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