ESAB | Mig 500i - Buddy™ Mig 500i | Instruction manual | ESAB Mig 500i - Buddy™ Mig 500i User manual

ESAB Mig 500i - Buddy™ Mig 500i User manual
GB
Buddy
™
Mig 500i
Instruction manual
0463 335 074 GB
20120507
Valid for serial no. 209-xxx-xxxx
GB
1 SAFETY .…………………………………………………………………….. 3
2 INTRODUCTION .………………………………………………………..… 5
2.1
Equipment ..…………………………………………………………………….….. 5
3 TECHNICAL DATA ………………………………………………………… 5
4 INSTALLATION …………………………………………………………… 6
4.1
4.2
4.3
Lifting instructions …………………………………………………………………. 6
Location …………………………………………………………………………….. 6
Mains supply ..………………………………………………………………………. 6
5 OPERATION ………………………………………………………………… 8
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
Connections and control devices ………………………………………………….8
Fault indication light ………………………………………………...……………… 8
Inductance ………………………………………………………………………….. 8
Wire feed speed / Ammeter……………………………………………………….. 8
Gas check / Weld mode ..……………………….………………………………….9
2S / 4S (Crater on / off) .…………………….…………………………………….. 9
Crater filling .………………………………………………………………………… 9
Creep start ..………………………………………………………………………… 9
Burnback …………………….……………………………………………………… 9
Turning on the power source……………………………………………….……... 10
Connection of welding and return cable …………………………………………. 10
MIG/MAG and FCAW-S welding………………………………………………….. 10
6 MAINTENANCE ……………………………………………………………. 10
6.1
6.2
Power source ...………………………………………………………………….…. 10
Welding leads and clamps.……………………………………………………..…. 10
7 FAULT TRACING ..………………………………………………………… 11
8 ORDERING OF SPARE PARTS .………………………………………… 11
DIAGRAM …………………………………………………………….……..… 12
ORDERING NUMBERS ………………………………………….……..…… 13
ACCESSORIES ……..………………………………………………………… 14
Rights reserved to alter specifications without notice.
-2© ESAB AB2012
GB
1
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:
● its operation
● location of emergency stops
● its function
● relevant safety precautions
● welding
2. The operator must ensure that:
● no unauthorized person is stationed within the working area of the equipment when it is
started up.
● no-one is unprotected when the arc is struck
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, flameproof 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 qualified electricians.
● Appropriate fire extinguishing equipment must be clearly marked and close at hand.
● Lubrication and maintenance must not be carried out on the equipment during operation.
-3© ESAB AB2012
GB
WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precautions when welding &
cutting.
Ask for your employer’s safety practices which should be based on manufacturers’ hazard data.
ELECTRIC SHOCK - Can kill
●
Install and earth the welding 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 work-piece.
●
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!
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 only.
ESAB can provide you with all necessary welding protection and accessories.
-4© ESAB AB2012
GB
2
INTRODUCTION
Mig 500i is a welding power source intended for MIG/MAG welding as well as for welding with
powder filled cored wire (FCAW-S) when coupled with Feed 402 wire feeder and associated
accessories.
ESAB's accessories for the product can be found on page 14.
2.1
Equipment
The power source is supplied with an instruction manual, 3m mains cable and 5m return cable with
clamp.
3
TECHNICAL DATA
Mig 500i
Mains voltage
400 V ± 15%, 3 ~ 50/60 Hz
Primary current
Imax
Ieff
37 A
29 A
Setting range
MIG/MAG
50 A / 16.5 V – 500 A / 39 V
Permissible load at MIG/MAG
60% duty cycle
100 % duty cycle
500 A / 39 V
387 A / 33.4 V
Power factor at maximum current
0.93
Efficiency at maximum current (MIG/MAG)
85%
Open-circuit voltage U0 max
70 V DC
Preset gas pre-flow
Preset gas post-flow
Preset creep start
Preset burn-back
0.5 sec
2.0 sec
Built-in
0.3 sec
Operating temperature
Transportation temperature
-10 to +40°C
-20 to +55°C
Dimensions lxwxh
Weight
Insulation class
Enclosure class
Application class
650 x 350 x 650 mm
58 kg
F
IP21
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. The duty cycle is valid for temperatures up to 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 IP21 is designed for indoor use.
-5© ESAB AB2012
GB
Application class
The symbol
indicates that the power source is designed for use in areas with increased
electrical hazard.
4
INSTALLATION
The installation must be executed by a professional
4.1
Lifting instructions
WARNING!
The handles are meant for manual handling of the power source only. For
mechanized handling, please use the lifting eyes.
WARNING!
The lifting eyes are meant for mechanized lifting of the power source only. Do
not attach any accessories such as welding cables, wire feeder or gas cylinder
when lifting the power source using these lifting eyes.
4.2
Location
Place the power source such that its cooling air inlets and outlets are not obstructed.
4.3
Mains supply
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
distribution network operator if necessary, that the equipment may be connected.
-6© ESAB AB2012
GB
Make sure that the welding power source is connected to the correct supply voltage and that it is
protected by the correct fuse rating. Please refer to the rating plate at the back of the machine for
the mains supply requirement. A protective earth connection must be made in accordance with
regulations.
Rating plate with supply connection data
Note! The welding power source is designed for connection to a 400 (380 - 415V) volt system with
four conductors. If the power source is to be used in countries with a higher or lower supply voltage,
the power source must be connected via a safety transformer.
Recommended fuse sizes and minimum cable area
Mig 500i
400 V ± 15%, 3 ph
Mains voltage
2
Mains cable area mm
4G6
Phase current I1eff
29A
Fuse
Anti-surge
32A
Type C MCB
32A
Note!
Use the welding power source in accordance with the relevant national regulations.
(Check with relevant national regulations)
-7© ESAB AB2012
GB
5
OPERATION
General safety regulations for the handling of the equipment can be found
on page 3. Read through before you start using the equipment!
5.1
Connections and control devices
1
Voltmeter
7
Crater voltage control (
)
2
Wire feed speed display / ammeter
8
Crater current control (
)
3
Inductance control (
9
Fault indication light (Yellow LED) ( )
4
Connection for wire feed unit (
10
Power indication light (White LED)
5
Connection (-)
11
Switch for 2-stroke / 4-stroke (Crater on/off)
6
Connection (+)
12
Gas check / weld mode
13
Mains power supply switch, 1 / 0
14
CO2 heater regulator socket (110Vac)
15
Resettable breaker for heater socket
11
12
)
)
1
10
2
9
15
8
14
13
3
7
4
5
6
5.2
Fault Indication Light (Yellow LED) ( ) (Pos 9)
The power source has a fault indication light that operates when one of the following events occur:1) Thermal overload - operates when machine has been used beyond its intended duty cycle. Fault
indication resets automatically when the temperature has fallen to a suitable temperature
2) Over/under voltage protection - operates when the mains input voltage exceeds the tolerance of
the machine. Fault indication would need to be reset manually by turning the main switch to off and
then back on again.
3) Internal machine fault - operates if there are faults in the machine. Please contact ESAB Service
technician for assistance.
5.3
Inductance (
) (Pos 3)
Higher inductance results in a wider weld pool and less spatter. Lower inductance produces a
harsher sound but a stable, concentrated arc.
Control of the inductance is especially important when short arc welding.
5.4
Wire feed speed display / Ammeter (Pos 2)
During preset, the meter will show wire feed speed in m/min. When welding, the meter will show
the welding amperage.
-8© ESAB AB2012
GB
5.5
Gas Check / Weld mode (Pos 12)
Gas check is used to measure that gas flow or to flush the gas hoses to clean them of any air and
moisture before commencing welding. Gas check is carried out with the voltage and wire feed
switched off.
5.6
2-stroke /4-stroke (Crater on/off) (Pos 11)
With 2 stroke, wire feed starts when the trigger switch is pressed in and ends when it is released.
With 4 stroke, the gas flow starts when the trigger switch is pressed in and the wire feed starts
when it is released. The welding process continues until the switch is pressed in again, the wire
feed stops and when the switch is released the post-flow starts. By switching to 4 stroke, it also
turns on the crater filling function. The crater voltage & current can be adjusted on the panel of the
power source.
5.7
Crater filling (Pos 7 & 8)
Crater filling helps to avoid pores, thermal cracking and crater formation in the weld when welding
stops.
The crater voltage & current control on the machine panel controls the full voltage and current
range of the machine. It is generally recommended that the crater voltage & current is set lower
than the welding voltage & current.
5.8
Creep start
Creep start means that the wire is fed at low speed until it comes into electrical contact with the
workpiece and then the speed increases to the set speed. The creep start timing has been preset
and cannot be changed.
5.9
Burnback
Burnback time is a delay between the time when the wire starts to brake until the time when the
power source switches off the welding voltage. The burnback timing has been preset and cannot
be changed.
5.10
Turning on the power source (Pos 13)
Turn on the mains power by turning the mains switch to the “1” position.
If the mains power supply should be interrupted while welding is in progress, and then be restored,
the power source will be energised.
Turn the unit off by turning the switch to the “0” position.
5.11
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 welding method or type of electrode used.
For MIG/MAG/FCAW-S welding, one end of the welding cable can be connected to the positive
terminal (+) or negative terminal (-) depending on the type of electrode used (The connecting
polarity is stated on the electrode packaging) and the other end of the welding cable is connected
to the wire feeder.
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.
-9© ESAB AB2012
GB
5.12
MIG/MAG and FCAW-S welding
An arc melts a continuously supplied wire. The weld pool is protected by shielding gas.
For MIG/MAG and FCAW-S welding, the power source is to be supplemented with:
●
wire feed unit
●
welding gun
●
connection cable between power source and wire feed unit
●
gas bottle with suitable regulator
6
MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized staff)
may remove the safety plates.
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.
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 down 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 gun and clamp
Wear parts should be cleaned and replaced at regular intervals in order to achieve trouble-free
welding.
- 10 © ESAB AB2012
GB
7
FAULT - TRACING
Try these recommended checks and inspections before sending for an authorized
service technician.
Type of fault
No arc.
●
●
The welding current is
interrupted during welding
●
●
●
The thermal cut-out trips
frequently
●
●
●
Poor welding performance
●
●
●
●
8
Corrective action
Check that the mains power supply switch is turned on.
Check that the welding and return cables are correctly
connected.
Check that the correct current value is set.
Check the mains power supply fuses.
Check whether the thermal cut-outs have tripped (a fault
light is displayed on the control panel).
Check the mains power supply fuses.
Check to see whether the air inlets & outlets are being blocked.
Make sure that you are not exceeding the rated data for the
welding power source (i.e. that the unit is not being overloaded)
Check that the welding power source is not clogged with dirt.
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.
ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
To find the required spare part, please refer to the Spare Parts List as shown on page 13.
Spare parts may be ordered through your nearest ESAB dealer. See the last page of this publication
to find the nearest ESAB office or dealers.
- 11 © ESAB AB2012
Mig 500i
Diagram
- 12 © ESAB AB2012
Mig 500i
Ordering Numbers
Ordering no.
Description
Type
0700 301 000
Welding power source
Buddy™ Mig 500i, 400V
0459 839 079
Spare parts list
Buddy™ Mig 500i, 400V
The spare parts list is available on the internet at www.esab.com
- 13 © ESAB AB2012
Mig 500i
Accessories
Buddy™ Feed 402. . . . . . . . . . . . . .. . . . . . . . 0700 301 200
Connection Set, 70mm2
15m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0700 301 300
25m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0700 301 301
Comprises of welding cable, gas hose & control cable
Wheel Kit, 10m . . . . . . . . . . . . . . . . . . . . . . . 0700 301 010
Comprises of 2 fixed & 2 swivel castor wheels
Trolley with Gas Tray. . . . . . . . . . . . . . . . . . 0700 301 011
- 14 © ESAB AB2012
Notes
- 15 © ESAB AB2012
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.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
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
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
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
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Africa
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
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
Distributors
Asia/Pacific
www.esab.com
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
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
MALAYSIA
ESAB (Malaysia) Sdn Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
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
www.esab.com
© ESAB AB
110915
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