ESAB ES 1450 User manual

GB
ES 1450
Instruction manual
0463 241 074 GB 110120 Rev. 1.0
1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
3
5
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
3 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
6
4.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1
Recommended fuse sizes and minimum cable area . . . . . . . . . . . . . . . . . . . . . . .
6
6
6
5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
5.1 Connections and control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Connection of welding and return cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 MMA welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.1
Striking the arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.2
Manipulation of electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.3
Anti-electrode pick-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.4
Joint form in MMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.5
Electrode selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
8
8
8
8
8
9
9
6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
6.1
Power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
7 FAULT-TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11
12
13
14
Rights reserved to alter specifications without notice.
TOCe
-2-
GB
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 ob­
served 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 equip­
ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in­
jury to the operator and damage to the equipment.
1.
Anyone who uses the equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding and cutting
2.
The operator must ensure that:
S no unauthorized 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 drafts
4.
Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves. Note! Do not use safety gloves when replacing wire.
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.
WARNING
Do not use the power source for thawing frozen pipes.
-3bh39de
GB
WARNING
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
S
Install and earth the 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!
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
This product is solely intended for arc welding.
ESAB can provide you with all necessary welding protection and accessories.
-4bh39de
GB
2
INTRODUCTION
ES 1450 is a general MMA arc welding power source.
ESAB's accessories for the product can be found on page 14.
2.1
Equipment
The power source is supplied with:
S
S
S
3 meter welding cable with electrode holder
3 meter return cable with return clamp
instruction manual.
3
TECHNICAL DATA
ES 1450
Mains voltage
Primary current Imax
Setting range
Permissible load at
15 % duty cycle
60 % duty cycle
100 % duty cycle
Power factor at maximum current
Efficiency at maximum current
Open-circuit voltage U0 max
Operating temperature
Sound pressure at no-load
Dimensions lxwxh
Weight
Enclosure class
Application class
230 V 1 $10%, 1 50/60 Hz
30.5 A
10 A / 20.4 V - 145 A / 25.8 V
145 A / 25.8 V
70 A / 22.8 V
55 A / 22.2 V
0.76
80 %
63 V
-10 to +40° C
<70 db (A)
280 x 120 x 220 mm
3.6 kg
IP 21S
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.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Apparatus marked IP21 are intended for indoor use.
Application class
The symbol
indicates that the power source is designed for use in areas with increased
electrical hazard.
-5bh39de
GB
4
INSTALLATION
The installation must be executed by a professional.
4.1
Location
Position the power source such that its cooling air inlets and outlets are not
obstructed.
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.
Rating plate with supply connection data
4.2.1
Recommended fuse sizes and minimum cable area
ES 1450
230V $10% 1 50/60 Hz
Mains voltage
Mains cable area
mm2
3 G 1.5
Phase current I1eff
12 A
Fuse anti-surge
16 A
NOTE! Use the power source in accordance with the relevant national regulations.
-6bh39de
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
Indicating lamp, white, power supply ON,
5
Mains power supply switch 1/O
2
Indicating lamp, yellow, overheating
6
Connection (+) for return cable or welding
cable
3
Knob for setting the welding current
7
Connection (-) for return cable or welding
cable
4
Connection for mains cable
5.2
Symbols
Power supply ON
5.3
Overheating
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 type of electrode used. The connecting polarity is
stated on the electrode packaging. Connect the welding cable to the termnial stated
on the electrode packaging.
Connect the return cable to the other output on the power source. Secure the return
current 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.
-7bh39de
GB
5.4
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.
5.5
MMA welding
5.5.1
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.
5.5.2
Manipulation of electrode
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];
weld
a small oscillation maybe neccessary to achieve
workpiece
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.
5.5.3
1
2
3
2
1 electrode moving
2 the electrode oscilliation (right & left)
3 the electrode move along weld
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.
-8bh39de
GB
5.5.4
Joint form in MMA
Butt joint
Corner joint
Lap joint
T joint
The common basic joint form: butt joint, corner joint, lap joint, & T joint.
5.5.5
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.
S
To ensure good quality weld, the electrode should
always be dried or dry stored. This to avoid hydrogen
inclusion. blowhols and cold cracks.
S
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.
S
In MMA welding the arc length is usually equal to
0.5-1.0 time of the electrode diameter. The basic
electrode’s arc length is not beyond the electrode
diameter, it’s better to choose the short arc welding;
the acid electrode’s arc length is equal to the electrode
diameter.
-9bh39de
GB
6
MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized
personnel) 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:
S
S
S
S
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.
7
FAULT-TRACING
Try these recommended checks and inspections before sending for an authorized
service technician.
Type of fault
Corrective action
No arc.
S
Check that the mains power supply switch is turned on.
S
Check that the welding current supply and return cables are
correctly connected.
S
Check that the correct current value is set.
S
Check to see whether the MCB has tripped.
S
Check whether the thermal cut-outs have tripped (indicated
by the orange lamp on the front panel).
S
Check the mains power supply fuses.
The thermal cut-out trips
frequently.
S
Check to see whether the dust filter is clogged.
S
Make sure that you are not exceeding the rated data for the
power source (i.e. that the unit is not being overloaded).
Poor welding performance.
S
Check that the welding current supply and return cables are
correctly connected.
S
Check that the correct current value is set.
S
Check that the correct electrodes are being used.
S
Check the gas flow.
The welding current is
interrupted during welding.
- 10 bh39de
GB
8
ORDERING
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
- 11 bh39de
K1 AC220−230/50/60HZ
bh39e
FAN
3
1
AC
AC
−
+
4
2
−24V
PTC
- 12 LED1
LED2VR1
Pr2
Pr1
OC1 OC2
FJ
DR1
DR2
DR3
DR4
DR5
DR6
DR7
DR8
DR6
DR5
DR2
DR1
IGBT
IGBT
DR8
DR7
DR4
DR3
IGBT
OC
IGBT
OC1
OC2
OC1
OC2
TRANS2
L?
OUT−
OUT+
Diagram
Edition 110120 Rev. 1.0
ES 1450
Ordering number
40 50 60
30
ES 1450
70
80
90
20
A 100
INVERTER DC WELDER CURRENT
Ordering no.
10
Denomination
Type
0700 300 880 Welding power source
ES 1450
0459 839 053 Spare parts list
ES 1450
The spare parts list is available on the Internet at www.esab.com
- 13 bh39o
Edition 110120 Rev. 1.0
ES 1450
Accessories
Return cable with clamp 3 m 16 mm2 . . . . . . 0700 300 863
Welding cable with electrode holder . . . . . . 0700 300 862
- 14 bh39a
Edition 110120 Rev. 1.0
NOTES
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
.............................................................................................................................................................
- 15 notes
ESAB subsidiaries and representative offices
South America
Distributors
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
www.esab.com
Asia/Pacific
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) Snd 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
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
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
SOUTH AFRICA
ESAB Africa Welding & Cutting Ltd
Durbanville 7570 - Cape Town
Tel: +27 21 975 8924
101217