ESAB | Buddy™ Arc 200 | Instruction manual | ESAB Buddy™ Arc 200 User manual

ESAB Buddy™ Arc 200 User manual
Buddy™
Arc 180
Arc 200
Instruction manual
0463 266 001 GB 20150424
Valid for: serial no. Arc 180: 31312108277
Arc 200: 31312108187
TABLE OF CONTENTS
1
SAFETY ................................................................................................................ 4
2
INTRODUCTION ................................................................................................... 7
2.1
Equipment............................................................................................................. 7
3
TECHNICAL DATA ............................................................................................... 8
4
INSTALLATION..................................................................................................... 9
4.1
Location ................................................................................................................ 9
4.2
Mains power supply............................................................................................. 9
4.2.1
Recommended fuse sizes and minimum cable area ......................................... 9
5
OPERATION ....................................................................................................... 10
5.1
Connections ....................................................................................................... 10
5.2
Connection of welding and return cable..........................................................10
5.3
Symbols and Control panels............................................................................. 11
5.4
Overheating protection...................................................................................... 11
5.5
MMA welding ...................................................................................................... 11
5.5.1
Welding current setting .................................................................................... 12
5.5.2
Striking the arc ................................................................................................. 12
5.5.3
Manipulation of electrode ................................................................................. 12
5.5.4
Anti-electrode pick-up ...................................................................................... 13
5.5.5
Joint forms in MMA .......................................................................................... 13
5.5.6
Electrode selection........................................................................................... 13
5.6
TIG welding......................................................................................................... 13
5.6.1
Welding current setting .................................................................................... 14
5.6.2
Striking an Arc “Live TIG- start”........................................................................ 14
5.6.3
Joint forms in TIG............................................................................................. 14
6
MAINTENANCE .................................................................................................. 15
6.1
Power source...................................................................................................... 15
6.2
Welding torch ..................................................................................................... 15
7
FAULT-TRACING................................................................................................ 16
8
ORDERING SPARE PARTS ............................................................................... 17
DIAGRAM .................................................................................................................. 18
ORDERING NUMBERS .............................................................................................20
ACCESSORIES .........................................................................................................21
Rights reserved to alter specifications without notice.
0463 266 001
© ESAB AB 2015
1 SAFETY
1
SAFETY
Users of ESAB 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 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
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 equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment when it
is started up
○ no-one is unprotected when the arc is struck or work is started with the equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could
become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified electrician
○ Appropriate fire extinquishing equipment must be clearly marked and close at hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Do not use the power source for thawing frozen pipes.
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© ESAB AB 2015
1 SAFETY
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices which should
be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
•
•
•
•
Install and earth the unit in accordance with applicable standards
Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing
Insulate yourself from earth and the workpiece
Ensure your working stance is safe
FUMES AND GASES - Can be dangerous to health
•
•
Keep your head out of the fumes
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
•
•
Protect your eyes and body. Use the correct welding screen and filter lens and
wear protective clothing
Protect bystanders with suitable screens or curtains
FIRE HAZARD
•
Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
NOISE - Excessive noise can damage hearing
•
•
Protect your ears. Use earmuffs or other hearing protection.
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!
CAUTION!
Read and understand the instruction manual before
installing or operating.
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.
CAUTION!
This product is solely intended for arc welding.
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© ESAB AB 2015
1 SAFETY
ESAB can provide you with all necessary welding protection and accessories.
DISMANTLING AND SCRAPPING
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
Welding equipment primarily consists of steel, plastic and non-ferrous metals, and must be
handled according to local environmental regulations.
Coolant must also be handled according to local environmental regulations.
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© ESAB AB 2015
2 INTRODUCTION
2
INTRODUCTION
Arc 180 and Arc 200 are welding power sources intended for use with coated electrodes
(MMA welding) and TIG welding (Live Arc).
ESAB's accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1
Equipment
The power source is supplied with:
•
•
•
3 meter welding cable with electrode holder
3 meter return cable with return clamp
Instruction manual
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© ESAB AB 2015
3 TECHNICAL DATA
3
TECHNICAL DATA
Arc 180
Arc 200
Mains voltage
230 V 1~ ± 10 %, 50/60 Hz
230 V 1~ ± 10 %, 50/60 Hz
Primary current I max
36 A
40.7 A
Setting range MMA
5 A / 20.0 V - 180 A / 27.2 V
5 A / 20.2 V - 210 A / 28.4 V
Setting range TIG
5 A / 10 V - 180 A / 17.2 V
5 A / 10.2 V - 210 A / 18.4 V
Permissible load at MMA
30 % duty cycle
180 A / 27.2 V
35 % duty cycle
200 A / 28.0 V
60 % duty cycle
125 A / 25.2 V
135 A / 25.4 V
100 % duty cycle
100 A / 24.0 V
120 A / 24.8 V
35 % duty cycle
180 A / 17.2 V
200 A / 18.0 V
60 % duty cycle
130 A / 15.2 V
135 A / 15.4 V
100 % duty cycle
100 A / 14.0 V
120 A / 14.8 V
Power factor at maximum
current
0.72
0.71
Efficiency at maximum
current
>80 %
>80 %
Open-circuit voltage U0 max 59.8 V
66.3 V
Operating temperature
-10 to +40°C
-10 to +40°C
Transportation temperature -20 to +55°C
-20 to +55°C
Sound pressure at no-load
<70 db (A)
<70 db (A)
Dimensions l × w × h
310 × 140 × 230 mm
360 × 140 × 230 mm
Weight
6.6 kg
7.5 kg
Enclosure class
IP 23S
IP 23S
Permissible load at TIG
Application class
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or
cut at a certain load without overloading. The duty cycle is valid for 40°C / 104°F.
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 intended 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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© ESAB AB 2015
4 INSTALLATION
4
INSTALLATION
The installation must be carried out by a professional.
4.1
Location
Position the power source such that its cooling air inlets and outlets are not obstructed. Also
position the power source so that the air inlet does not get clogged with unwanted material.
4.2
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 outlet shall have a protective earth
connection.
A. Rating plate with supply connection data
4.2.1
Recommended fuse sizes and minimum cable area
Arc 180
Mains voltage
Arc 200
230V 1~ ± 10%, 50/60 Hz
Mains cable area mm2
3 G 2.5
3 G 2.5
Phase current I1eff (TIG)
12.5 A
16.6 A
Phase current1eff (MMA)
16.0 A
24.1 A
NOTE!
Use the power source in accordance with the relevant national regulations.
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© ESAB AB 2015
5 OPERATION
5
OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
5.1
Connections
1. Control panel
4. Mains power supply switch 1/O
2. Connection (-) for return cable, welding
5. Connection for mains cable
cable or TIG torch
3. Connection (+) for return cable or welding
cable
5.2
Connection of welding and return cable
The power source has two outputs, a negative [-] terminal (2) and a positive [+] terminal (3),
for connecting welding and return cables.
For MMA process the output to which the welding cable is connected depends on the type of
electrode, please refer to electrode packaging for information relating to the correct electrode
polarity.
For optional TIG process, connect the TIG torch power cable to the negative [-] terminal (2).
Connect gas inlet nut to a regulated shielding gas supply.
Connect the return cable to the remaining welding terminal on the power source. Secure the
return cable's contact clamp to the work piece and ensure that there is good contact.
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© ESAB AB 2015
5 OPERATION
5.3
Symbols and Control panels
Arc 180
Arc 200
5.4
Power ON Indicating lamp,
white, power supply ON
Overheating Indicating lamp,
yellow, overheating
Scratch TIG
MMA welding
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.
NOTE!
If the utilization of the power source is to high it might get
overheated. See permissable load in the TECHNICAL
DATA chapter in this manual.
If the air inlet or outlet is blocked or get clogged with
unwanted material the power source might get
overheated. Make sure that the airflow through the power
source is not blocked.
5.5
MMA welding
Move process selector switch to desired welding process.
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© ESAB AB 2015
5 OPERATION
NOTE!
Power source output is enabled.
Check welding cable polarity selection matches electrode requirements. Select desired
welding current level.
5.5.1
Welding current setting
The Arc 180 power source has an adjustable welding current from
5 to 180 Amps.
The Arc 200 has an adjustable value from 5 to 200 Amps.
Current
5.5.2
Striking the arc
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 immediately
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 and then raise it to give an appropriate arc length (approx. 2 mm). If the arc
is too long, it will crackle and split before finally going out completely. Once the arc has been
struck, move the electrode from left to right. The electrode should be at an angle of 60° to the
metal.
5.5.3
Manipulation of electrode
In MMA welding, there are three motions to being matched in the end of electrode: the
electrode moving to the molten pool along axes [1]; a small oscillation maybe neccessary to
achieve the desired width of the melt pool [2]; the electrode moving along welding way [3].
The operator can choose the manipulation of electrode based on welding joint sharp, welding
position, electrode spec, welding current and operation skill, etc.
1. electrode moving
2. the electrode oscilliation (right and left)
3. the electrode move along weld
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4. workpiece
5. weld
6. electrode
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© ESAB AB 2015
5 OPERATION
5.5.4
Anti-electrode pick-up
If, during the welding, the electrode would get in direct contact (touching) with the workpiece
to form short circuit, the welding current will drop to a miminum to prolong the life of the
electrode.
5.5.5
Joint forms in MMA
Butt joint
5.5.6
Corner joint
Lap joint
T joint
Electrode selection
The electrode diameter selection is based on
the workpiece thickness, welding position,
joint form, welding layer, etc. Please refer to
the recommendations on the electrode
package for further details.
•
To ensure good quality weld, the
electrode should always be dried or dry
stored. This to avoid hydrogen inclusion,
blowholes and cold cracks.
•
In the welding process, the arc must not
be too long; otherwise, it will cause
unstable arc burning, large spatter, light
penetration, undercut, blowhole, etc. If the
arc is too short, it will cause electrode
stick.
5.6
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.
TIG welding is particularly useful where high quality is demanded and for welding thin plate.
The power sources also have good characteristics for TIG welding.
In order to TIG weld, the power sources must be equipped with:
•
a TIG torch with gas valve (see in the "ACCESSORIES" chapter of this manual)
•
a welding gas cylinder (a suitable welding gas)
•
a welding gas regulator (suitable gas regulator)
•
tungsten electrode
•
suitable auxiliary material, if necessary.
Move process selector switch to desired welding process.
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© ESAB AB 2015
5 OPERATION
NOTE!
Power source output is enabled.
Check welding cable and TIG torch polarity matches electrode requirements.
Select desired welding current level.
5.6.1
Welding current setting
The Arc 180 power source has an adjustable
welding current from 5 to 180 Amps. The Arc
200 has an adjustable value from 5 to 200
Amps.
5.6.2
Current
Striking an Arc “Live TIG- start”
With “Live TIG start” the arc strikes when the tungsten electrode is brought into contact with
the workpiece and then lifted away from it.
5.6.3
Joint forms in TIG
Butt joint
0463 266 001
Corner joint
Lap joint
- 14 -
T joint
© ESAB AB 2015
6 MAINTENANCE
6
MAINTENANCE
NOTE!
Regular maintenance is important for safe, reliable operation.
CAUTION!
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.
6.1
Power source
Check regularly that the welding power source is not clogged with dirt.
How often and which cleaning methods apply depend on:
•
welding process
•
arc time
•
placement
•
surrounding environment
It is normally sufficient to blow the power source with dry compressed air (reduced pressure)
once a year.
Clogged or blocked air inlets and outlets otherwise result in overheating.
6.2
Welding torch
Wear parts should be cleaned and replaced at regular intervals in order to achieve
trouble-free welding.
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© ESAB AB 2015
7 FAULT-TRACING
7
FAULT-TRACING
Try these recommended checks and inspections before sending for an authorized service
technician.
Type of fault
Corrective action
No arc.
•
Check that the mains power supply switch is
turned on.
•
Check That the mains input Voltage is not too low
or too high. The yellow LED will illuminate if the
input is below or above the recommended levels
and the machine is at normal working temperature.
•
Check that the welding current supply and return
cables are correctly connected.
•
Check that the correct current value is set.
•
Check to see whether the MCB has tripped.
•
Check whether the thermal cut-outs have tripped
(indicated by the yellow lamp on the front panel).
•
Check the mains power supply fuses.
•
Check to see whether the dust filter is clogged.
•
Make sure that you are not exceeding the rated
data for the power source (i.e. that the unit is not
being overloaded). See permissable load in the
TECHNICAL DATA chapter in this manual.
Make sure that the positioning of the power source
is such that its cooling air inlets and outlets are not
obstructed.
The welding current is interrupted
during welding.
The thermal cut-out trips frequently.
•
Poor welding performance.
0463 266 001
•
Check that the welding current supply and return
cables are correctly connected.
•
Check that the correct current value is set.
•
Check that the correct electrodes are being used.
•
Check the gas flow. When in Live Tig Mode using
optional ET 17V Tig Torch.
- 16 -
© ESAB AB 2015
8 ORDERING SPARE PARTS
8
ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised service
technician. Use only original spare and wear parts.
Arc 180, Arc 200 is designed and tested in accordance with the international and
European standards EN 60974-1 and 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.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of this
publication.
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© ESAB AB 2015
DIAGRAM
DIAGRAM
0463 266 001
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© ESAB AB 2015
DIAGRAM
0463 266 001
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© ESAB AB 2015
ORDERING NUMBERS
ORDERING NUMBERS
Ordering no.
Denomination
Type
0700 300 885
Welding power source
BuddyTM Arc 180
0700 300 887
Welding power source
BuddyTM Arc 200
0459 839 066
Spare parts list
BuddyTM Arc 180 and Arc 200
Technical documentation is available on the Internet at: www.esab.com
0463 266 001
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© ESAB AB 2015
ACCESSORIES
ACCESSORIES
0700 006 901 Return cable with clamp
200A, OKC 50, 3m
0700 006 885 Return cable with clamp
200A, OKC 50, 5m
0700 006 900 Welding cable
200A, OKC 50, 3m
0700 006 884 Welding cable
200A, OKC 50, 5m
0700 300 861 TIG 17 torch
4m
0463 266 001
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© ESAB AB 2015
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Heist-op-den-Berg
Tel: +32 15 25 79 30
Fax: +32 15 25 79 44
BULGARIA
ESAB Kft Representative Office
Sofia
Tel: +359 2 974 42 88
Fax: +359 2 974 42 88
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB International AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
www.esab.com
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
SOUTH AFRICA
ESAB Africa Welding & Cutting
Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
USA
ESAB Welding & Cutting
Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacific
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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