ESAB Tradestig Dual 151i Service manual

 MUREX“
— Tradestig Dual 1511
- SERVICE MANUAL
—
MUREX
CONTENTS
INTRODUCTION
RADIO INTERFERENCE
SPECIFICATION
INSTALLATION & CONTROLS
PARTS LIST
FAULT FINDING GUIDE
CIRCUIT DIAGRAM
AUTOSWITCH PCB OPERATION
AUTOSWITCH PCB LAYOUT
MAIN INVERTER PCB LAYOUT
PCB INTERCONNECTIONS
HF & GAS VALVE PCB LAYOUT
PAGE
2-4
56
7-8
10
11
12°
13
14
MUR
INTRODUCTION
The Tradestig Dual 151i is an inverter based DC power
source suiting both TIG and MMA welding methods. The |
unit can operate from either 230V or 110V single phase
electricity, see specification, and supplies up to 150A
welding output. Mains voltage selection is automatic, the
151i reads the supply voltage and sets the internal
circuitry automatically.
Front panel controls enable the operator to set welding
current and siope down time. The unit incorporates a gas
solenoid and a post purge time control is available on the
control panel.
Inbuilt into the unit is an electronic non-contact TIG arc
ignition system. Either 2 or 4 stroke torch switch TIG
modes can be selected as well as MMA. A 14 pin remote
control socket enables an FC-5B foot control to be used
for bench work and the like. A fan mounted in the rear of
the housing cools the internal components. A thermal
sensor protects the components from excessive
temperatures if the duty is exceeded. A manually
resettable circuit breaker on the front panel protects the
unit against excessive primary current.
RADIO INTERFERENCE
1. Murex welding power sources have been designed to
high standards of electromagnetic compatibility.
However, arc welding, by its very nature, generates
radio-frequency energy and may cause interference. By
installing and using the equipment correctly, in
accordance with these instructions, the problems. of
interference may be minimised.
9. This equipment satisfies the requirements of the EU
Directive 89/336/EC on EMC and complies with the limits
in EN 50 199, ‘EMC product standard for arc welding
equipment’. These limits are designed to provide
reasonable protection against interference in heavy
industrial areas. | |
3, If this equipment is used in domestic areas, eg. for
repair or maintenance, particular care should be taken.
The time of day should be chosen and the duration of
welding limited, to minimise any potential problems.
4, If this equipment caused interference the guidance
given below should be considered. If a solution cannot be
found please contact your distributor or the manufacturer.
5. Before installing this welding equipment an assessment
should be made of potential EMC problems that may occur.
It is good practice not to install welding equipment next to
computers or safety critical control circuits, eg electronic
machine guards, unless they have been suitably protected.
6. Primary cabling and welding cables should be kept
separate to other mains wiring and control, signalling or
communications leg telephone) cables. If interference
occurs then greater separation or re-routing should be
considered. Welding cables should be kept as short as
practically possible.
7. Interference may also be reduced by separating the
welding equipment from the other equipment affected. A
partition, brick wall or particularly, a metal screen will also
reduce interference. Earthing and equi-potential bonding
should also be considered but guidance should be sought
from a competent person, the distributor or manufacturer.
3. To ensure continued compliance to the EMC Directive
this equipment should be routinely maintained according
to the manufacturers instructions and using only approved
spare. parts. in particular, the spark gaps of HF units
should be adjusted and maintained according to the
manufacturers recommendations. |
9. All access and service door and covers should be
closed and properly fastened when the equipment is
being used. This equipment should not be modified in
any way except for those changes and adjustments
approved by the manufacturer.
|
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SPECIFICATION 4, -Ve Outlet
Input o |
Mains Supply 230V/110V 1 phase 50/60Hz OR RO he E De TE M vue + on 195 ЦЕ
Power (max) 4.8 KW (efficiency = 80%) came ction (+v ele ctrod e) g this is usually the work
KVA (max) 6 KVA (power factor = 0.8) ;
Fuse 230V 16A slow (13A for most
applications) 5. Gas Outlet to Torch
Fuse 110V 32A slow
| Connect the TIG torch gas hose to this fitting using a 1/4”
Output BSP RH coupling.
230V 110V
Supply Supply 6. Torch Switch Socket (2 pin)
Current Range 10 - 150A 10 - 120A Ка torch mounted switch is being used connect it here
Rating 25% duty - 120A using the matching 2 pin amphenol plug.
Rating 60% duty 150A 85A |
Rating 100% duty 100A ESA
OCV 70V 70V 7. Remote Control Socket (14 pin)
. For connection of a remote control device like the FC-5B
Dimensions foot control unit. Connection of a remote control disables
Length 360mm both start and main current settings. The remote control
Width 155mm provides full range control up to 150A.
Height 320mm
Weight 11Kg (net) | |
8. Power Switch
Standards
EN60974-1 & EN50199
INSTALLATION & CONTROLS, see Fig 1
1. Mains Input Cable (rear panel)
Connect to a suitable 230V or 110V single phase electricity
supply, see specification. The green/yellow earth lead
must be securely connected to earth. A switched outlet
containing suitable fusing should be used, refer to
specification for fusing details. If in doubt consult a
qualified engineer/electrician.
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2. Gas inlet Hose (rear panel)
Connect to the Argon cylinder regulator/flowmeter outlet
using the 3/8 BSP RH nut & nipple supplied with the
package. The regulator must be set to deliver Argon at 30
psi (otherwise the flowmeter will not read accurately).
3. +Ve Outlet
For TIG welding applications connect to the work using a
suitable work return lead and clamp. For MMA this is usually
the connection point for the electrode holder (+ve electrode).
Setting the power switch to on energises the internal
circuitry. The 151i automatically sets itself for either 110 or
230V as necessary.
9. Process Mode Selector Switch
Two different TIG operating modes are provided as weli as
MMA. The TIG modes are as follows:
a) 2 stroke (with HF) - The normal method for TIG welding
using non-contact arc striking. Press the torch switch (or
foot control) to start welding. Release the torch switch to
initiate the down-slope and stop welding.
b) 4 stroke (with HF) - For long duration welds the torch
switch can be electronically latched. Press to initiate the
TIG arc, once the arc is struck the switch can be released.
Repressing and holding the switch initiates the current
slope down. Provided the torch switch is held the welding
current will remain at minimum after the slope down is
completed. Releasing the torch switch at any time during
or after the slope down immediately turns off the arc.
c) MMA - When MMA is selected open circuit voltage is
immediately available at the output terminals and the HF
and gas control circuitry are disabled.
10. Welding Current Control
Sets the main welding current in the range 10 to 150A.
When using the unit on 110V supplies, MMA welding at
currents in excess of 100-120A may cause the mains
circuit breaker, see 14 below, to trip. |
MUR
11. Slope Down Time Control
in order to allow the welder crater to fill-up before
extinguishing the TIG arc, current can be reduced slowly to
background level before arc off. This control sets the time
for the down slope in the range 0-10 seconds. Setit to a
minimum when using a foot control unit.
12. Post Gas Purge Time Control
Sets the duration of the shielding gas flow after the TIG arc
is extinguished. Postflow time can be set up to 20 seconds.
13. Over Temperature Light
In the event the unit is over-dutied an internal temperature
sensor will switch off welding output and the over
temperature light will illuminate. In this event leave the unit
switched on with the fans running. Reset is automatic after
the unit has cooled.
14. Circuit Breaker (25A)
In the event that the mains input supply current exceeds
safe levels the front panel mounted circuit breaker will trip.
To reset the breaker switch off the unit and depress the
black reset button.
Fig 1. CONTROLS AND CONNECTIONS
10. Welding Current Control
13. Thermal Overload Indicator
9. Process Mode Selector Switch
6. Torch Switch Socket
3. +Ve Qutlet Work return
connection when TIG welding
*
4. -Ve Outlet Torch connection
point when TIG welding
11. Slope Down Time Control
7. Remote Control Socket
12. Post Purge Time Control
8. Power On/Off Switch
14. Circuit Breaker
Gas Outlet to TIG torch
Rear Panel Not Shown:
1. Mains Input Cable
2. Gas Inlet Hose
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Description
Gas Solenoid Valve
Control Transformer
Voltage Selection PCB
HF Generator PCB
Control PCB |
HF Coupling Transformer
Inverter PCB Ass'y
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Description Cct Reference
Dinz Socket -
Knob (small) ~~ -
Knob (large) -
LED (yellow) | DL
14 pin Socket | CN1
2 pin Socket CN2
Power On/Off Switch St
Circuit Breaker 25A CB
1/4" Bulkhead Fitting ;
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Tradestig Dual 151i -
FAULT FINDING GUIDE
Symptom
| Checks (using 230V Supply) _
Unit dead, no green pilot light
- Mains supply/fuse
- Remove top cover:
Inspect for obvious signs of damage
Check for 230Vac output from EMI filter
- Check for 230Vac output from back of
mains switch -
Pilot light is on but fan does not run and
there is no OCV* in MMA mode
- Check for 230Vac at fan terminals
- Check for 230Vac between connection
A2A of main inverter PCB and A2 of
autoswitch PCB. If not check the 25A
Circuit Breaker .
- Check for 230Vac between Al and A2
of the autoswitch PCB. If not suspect
resistor R1/R2 on main inverter PCB are
open circuit. Either replace resistors or
inverter PCB
- Check for 230Vac at the auxiliary
transformer T1 primary, if not suspect
autoswitch PCB
No OCV* in MMA mode but pilot light
is on and fan runs |
- Check for 320Vdc across de side of
input rectifier bridge RS1 оп тат |
inverter PCB —
- Check 18Vac supply from auxiliary
transformer T1 to main inverter PCB
Thermal overload indicator ¢ on but unit 1S
cold
- Check thermal sensor soldered
connections to back of inverter PCB
above main output rectifier heatsink
No HF or gas flow in TIG modes
‘- Check the 4 way ribbon cable to the
front panel control PCB is properly
connected
- Check the fuse (0.5A 20mm) mounted
on the HF/gas control PCB. Note that the
HF & gas solenoid are powered by
230Vac input at A3/A4 from the primary
of the auxiliary transformer T1 |
| - Check there is +24 Vdc between pins 1. |
and 4 of the connector CN1, note that pin
4 is “Ov”. This is supplied from the main
inverter PCB via the front panel control
PCB - —°
-In TIG 2S mode disconnect one of the
connections from the HF/gas control PCB
to the HF coupling transformer. Close
the torch switch (put a jumper between
the 2 pins in the torch switch socket) and
measure the dc voltage between pins 2 &
A and also between pins 3 & 4 of CN1.
Both voltages should be 10-12Vdc. If not
the front panel control PCB is defective
- If all above OK replace the HF/Gas
control PCB :
OCV* reduced or welding current
unsteady and current control uneven
- Check wiper voltage of current control
pot P1** varies smoothly over the range
0-SVdc w.r.t. the min end of the pot
*OCV should be 70Vdc +- 5%
**100kohm a
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Printed in England
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Murex Welding Products Limited
Hertford Road, Waitham Cross,
Herts. ENS 7RP. England
Telephone: Lea Valley (01992) 710000