Murex Tradestig AC 220, Instruction Manual And Spare Parts List

Page 1: ...GB Valid for serial no 827 xxx xxxx 0460 475 074 090227 Tradestig AC 220 Tradestig AC 220a Instruction manual and spare parts list ...

Page 2: ...NCE 9 7 1 Inspection and cleaning 10 8 FAULT TRACING 10 9 CONTROL PANEL 10 9 1 Tradestig AC 220 11 9 2 Tradestig AC 220a 12 10 TIG WELDING 13 10 1 Settings Tradestig AC 220 13 10 2 Settings Tradestig AC 220a 13 10 3 Symbol and Function explanations 14 10 4 Hidden TIG functions 18 11 MMA WELDING 20 11 1 Settings Tradestig AC 220a 20 11 2 Symbol and Function explanations 20 11 3 Hidden MMA functions...

Page 3: ...el 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...

Page 4: ...rn 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 o...

Page 5: ...ig AC 220 Tradestig AC 220a See the detailed description of the control panels section No 9 1 4 TECHNICAL DATA Tradestig AC 220 Tradestig AC 220a Mains voltage 230V 10 1 50 60 Hz Mains supply Zmax 0 28 ohm Primary current Imax TIG Imax MMA 27 A 25 A No load power demand when in the energy saving mode 6 5 min after welding 40 W Setting range TIG AC DC MMA 3 220 A 4 160 A Ignition voltage 11 5 kV Pe...

Page 6: ... a percentage of a ten minute period that you can weld at a cer tain load without overloading The duty cycle is valid for 40 C The duty cycle is valid for 40 C ambient temperature 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 designed for indoor and outdoor use Application class The symb...

Page 7: ...ponsibility of the installer or user of the equipment to ensure by consultation with the distrubution network operator if necessary that the equipment may be connected Check that the welding power source is connected to the correct mains power supply voltage and that it is protected by the correct fuse size A protective earth connection must be made in accordance with regulations Rating plate with...

Page 8: ... range of the machine on a 16 A fuse The PFC also protects the machines against fluctuating mains voltage and makes it safer to use with a generator Tradesarc 200 can operate with extra long mains cables over 100 m giving you a very larger working radius 6 2 Connections and control devices 1 Connection for remote control unit 6 Connection for return cable 2 Control panel 7 Mains switch 3 Connectio...

Page 9: ...ch to the 0 position Whether the mains power supply is interrupted or the power unit is switched off in the normal manner welding data will be stored so that it is available next time the unit is started 7 MAINTENANCE Regular maintenance is important for safe reliable operation Only those persons who have appropriate electrical knowledge authorized personnel may remove the safety plates to connect...

Page 10: ...t 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 the mains power supply The welding current is interrupted during welding S Check to see whether the thermal cut outs have tripped S Check the mains power supply fuses The thermal cu...

Page 11: ...ke or 4 stroke Setting from panel and connecting remote control unit Display of VRD function reduced open circuit voltage is active or inactive Choice of current indication A or seconds s during welding in the display Indication of which unit of measurement is used mm or inch Choice of parameter for material thickness slope down or gas post flow Indication of selected material thickness mm inch In...

Page 12: ... stroke Setting from panel program change with torch trigger switch or connecting remote control unit Display of VRD function reduced open circuit voltage is active or inactive Indication of which parameter is shown in the display current voltage percentage seconds or frequency Choice of current indication A or voltage indication V during welding in the display Indication of selected setting param...

Page 13: ... 4 2 These functions cannot be changed while welding is in progress 10 2 Settings Tradestig AC 220a TIG without pulsing AC DC and TIG with pulsing DC Function Setting range In steps of Default value HF LiftArc t 2 HF or LiftArct LiftArct 2 4 stroke 2 2 stroke or 4 stroke 2 stroke Gas pre flow time 1 0 5 s 0 1 s 0 5 s Slope up time 0 10 s 0 1 s 0 0 s Slope down time 0 10 s 0 1 s 1 0 s Gas post flow...

Page 14: ... the electrode are protected by shielding gas Alternating current The advantages of alternating current are reduced risk of magnetic arc blow and good oxide break up capacity when welding aluminium Direct current A higher current produces a wider weld pool with better penetration into the workpiece Pulsed current only DC Pulsing is used for improved control of the weld pool and the solidification ...

Page 15: ...kground current which along with the time for pulse current gives the pulse period Slope down TIG welding uses slope down by which the current falls slowly over a controlled time to avoid craters and or cracks when a weld is finished Gas post flow This controls the time during which shielding gas flows after the arc is extinguished Balance Setting the balance between the positive electrode and neg...

Page 16: ...es the arc when the electrode is brought into contact with the workpiece and then lifted away from it Striking the arc with the LiftArc functiont Step 1 the electrode is touched on to the workpiece Step 2 the trigger switch is pressed and a low current starts to flow Step 3 the welder lifts the electrode from the workpiece the arc strikes and the current rises automatically to the set value ...

Page 17: ... 55 3 2 Green WP 65 65 3 2 Black WL10 60 60 3 2 Black WL10 70 70 4 0 Green WP 70 75 4 0 Green WP 80 85 4 0 Black WL10 65 65 4 0 Black WL10 70 75 WP Pure tungsten electrode WL10 Lantha alloyed tungsten electrode 2 stroke Gas pre flow Slope up Slope down Gas post flow Functions when using 2 stroke control of the welding torch In the 2 stroke control mode pressing the TIG torch trigger switch 1 start...

Page 18: ...to the set pilot current with slope down if in use When the trigger switch is released again 4 the arc is extinguished and any gas post flow occurs Active panel Settings are made from the control panel Changing trigger data This function permits changing between different welding data memories by a double press on the trigger of the welding gun Only applies for TIG welding Remote control unit Sett...

Page 19: ...icro pulse the machine must be in the pulsed current function The value for pulse time and background current is normally 0 01 2 50 seconds By using the micro pulse the time can go down to 0 001 seconds When the micro pulse function is active times that are shorter than 0 25 seconds are shown in the display without decimal points Min current Used to set the minimum current for the remote control T...

Page 20: ...icated by a lit VRD LED The VRD function is deactivated when the system senses that welding has started If the VRD function is activated and open circuit voltage exceeds the 35 V limit this is indicated by an error message 16 appearing in the display and welding cannot be started whilst the error message is displayed NOTE The VRD function is not active LED has gone out on delivery Contact an autho...

Page 21: ...n determining how the current changes in response to a change in the arc length A lower value gives a calmer arc with less spatter Drop welding Drop welding can be used when welding with stainless electrodes The function involves alternately striking and extinguishing the arc in order to achieve better control of the supply of heat The electrode needs only to be raised slightly to extinguish the a...

Page 22: ...are shown alternately If several faults have been detected only the code for the last occurring fault is displayed Press any function button or turn the knob to remove the fault indication from the display NOTE If the remote control is activated deactivate the remote control by pressing to remove the fault indication 13 1 List of fault codes U 0 welding data unit U 2 power source U 5 AC unit U 1 c...

Page 23: ...ented Action Turn off the mains power supply to reset the unit Send for a service technician if the fault persists E 9 U 1 U 5 Faulty 24 V 15 V supply voltage The supply voltage is too high or too low The current welding process is stopped and starting is prevented Action Turn off the mains power supply to reset the unit Send for a service technician if the fault persists E 12 U 0 U 1 U 4 U 5 Comm...

Page 24: ... with AC unit The control panel has lost contact with the AC unit The current welding process stops Action Send for a service technician if the fault persists E 26 U 0 Program operating fault Something has prevented the processor from performing its normal tasks in the program The program restarts automatically The current welding process will be stopped This fault does not disable any functions A...

Page 25: ...astic and non ferrous metals and must be handled according to local environmental regulations Coolant must also be handled according to local environmental regulations Do not dispose of electrical equipment together with normal waste In observance of European Directive 2002 96 EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law electrical equipmen...

Page 26: ...Assembly instructions 26 bt33m11a 26 ...

Page 27: ...R0460 475 074 E090227 P27 27 p ...

Page 28: ...Edition 090227 Diagram 28 bt33e ...

Page 29: ...Edition 090227 29 bt33e ...

Page 30: ...R0460 475 074 E090227 P30 30 p ...

Page 31: ...60 750 881 Tradestig AC 220a 230 V 50 60 Hz with MMA kit Spare parts are to be ordered through the nearest MUREX agency Kindly indicate type of unit serial number denominations and ordering numbers according to the spare parts list Maintenance and repair work should be performed by an experienced person and electrical work only by a trained electrician Use only recommended spare parts ...

Page 32: ... 003 Side panel AA14 1 0460 265 001 Strap AA15 2 0468 497 001 Holder AA16 1 Nut Included in item AA51 M8 AA17 1 0459 269 002 Gas connection Included in item AA51 AA18 1 Socket 2 pole included in item AA52 29XS4 AA19 1 0457 626 001 Protection cap AA20 1 0458 681 897 Cable with connectors XS25 XP5 AA21 1 0194 227 003 Clamp AA22 1 0366 285 001 Protection cap AA23 2 0366 247 001 Nut AA24 2 0366 306 00...

Page 33: ...0459 183 880 Mains module Includes items AA1 switch AA2 mains cable with plug cable clamp and two ferrite rings 2L1 AA51 0460 379 890 Front complete Includes items AA6 AA11 AA16 AA17 AA18 AA19 AA20 AA21 AA22 AA23 AA24 AA52 0459 280 892 Cable set Including item AA18 2 pole socket 29XS4 5 pole socket 29XS6 and the wires between them ...

Page 34: ...rmer Includes main transformer socket 15XS4 socket 15XS6 thermal switch 15ST1 15TM1 AB7 0487 303 880 Secondary board 15AP2 AB8 1 0459 273 001 Earth bracket AB9 1 0194 158 004 Capacitor 2200 uF 450 V DC 15C1 AB10 1 0458 065 002 Fan 24 V DC With cables and socket 15XS3 15EV1 AB11 1 Circuit board See item AB51 15AP1 AB12 1 Semiconductor module See item AB51 AB13 1 0468 030 880 Shunt 15RS1 AB14 1 0459...

Page 35: ...Tradestig AC 220 Tradestig AC 220a R0460 475 074 E090227 P27 35 bt38mab1 ...

Page 36: ... circuit diagram Item Qty Ordering no Denomination Notes C AC1 1 0193 054 005 Solenoid valve 230 V AC 10YV1 AC2 1 Nut ML6M MF10x1 AC3 1 0456 496 001 Hose D 9 5 mm L 0 57 metre reinforced PVC AC4 1 0487 028 880 Circuit board TIG 10AP1 AC5 1 0460 135 002 HF coil 10TV1 10XS1 AC6 1 0459 258 001 Coil bracket ...

Page 37: ...Tradestig AC 220 Tradestig AC 220a R0460 475 074 E090227 P27 37 bt33sac1 AH 0859 ...

Page 38: ...18XS3 AD5 1 0467 801 002 Fan 24VDC socket 18XS4 included 18EV1 AD6 2 Spacer M5x20 AD7 1 0459 751 882 Inductor 15L1 AD8 2 Spacer TCBS 10R AD9 2 0460 112 001 Bar HF AD10 1 0460 114 001 Bar plus AD11 1 0460 113 001 Bar minus AD12 1 0460 152 980 Cable set coarse K9 K10 K11 K12 AD13 1 AC Power board See item AD50 18AP2 SPARE PARTS SETS Item Qty Ordering no Denomination Notes AD50 1 0459 384 885 AC Powe...

Page 39: ...Tradestig AC 220 Tradestig AC 220a R0460 475 074 E090227 P27 39 bt33sad1 ...

Page 40: ...MA3 MA4 MA5 MA6 and MA7 1 0460 476 886 Operating panel complete Tradestig AC 220a includes item MA1 MA2 MA3 MA4 MA5 MA6 and MA7 MA1 1 0460 477 885 Operating panel Tradestig AC 220 MA1 1 0460 477 886 Operating panel Tradestig AC 220a MA2 1 0460 420 001 Insulation sticker MA3 2 0455 661 012 Rivet plastic MA4 2 Nut M4 MA5 1 0193 700 711 Ribbon cable with connectors 34 pole MA6 1 0487 550 880 Circuit ...

Page 41: ...R0460 475 074 E090227 P41 41 p ...

Page 42: ...ent 0459 491 880 Remote control unit M1 10Prog CAN Choice of on of 10 programs MIG MAG voltage deviation TIG and MMA current deviation 0459 491 882 Remote control unit AT1 CAN MMA and TIG current 0459 491 883 Remote control unit AT1 CF CAN MMA and TIG rough and fine setting of current 0459 491 884 Welding cable kit Tradestig AC 220 Return cable kit Tradestig AC 220 0700 006 900 0700 006 901 Remote...

Page 43: ... 43 bt38a11a Strap 0460 265 001 Cable holder 0460 265 002 Shoulder holder 0460 265 003 Trolley for 5 10 litre gasbottle 0459 366 885 Trolley for 20 50 litre gasbottle 0459 366 886 Trolley for 20 50 litre gasbottle 0460 330 880 Tig torch TXH 200 4 m 0460 012 840 ...

Page 44: ...R0460 475 074 E090227 P27 Tradestig AC 220 Tradestig AC 220a 44 bt38a11a Foot pedal TI Foot CAN 0460 315 880 AH 0836 Cooling unit Tradescool 0460 144 881 ...

Page 45: ... 45 notes NOTES ...

Page 46: ...R0460 475 074 E090227 P46 46 paut ...

Page 47: ... 47 notes NOTES ...

Page 48: ...Murex Welding Products Ltd Hanover House Queensgate Britannia Road Waltham Cross Hertfordshire EN8 7TF England Please ensure that this Operating Manual is available to the user of the equipment ...