ESAB Aristotig 405 AC/DC Bedienungsanleitung

Bruksanvisning Manuel d´instructions

Brugsanvisning Gebruiksaanwijzing

Bruksanvisning Instrucciones de uso

Käyttöohjeet Instruzioni per l´uso

Instruction manual Manual de instruções

Betriebsanweisung Οδηγίες Χρήσεως

Aristotig 405

AC/DC

DTG 405

0458 165 -001 030827 Valid for Serial NO917 XXX-XXXX

- 2 -

SVENSKA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DANSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

NORSK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SUOMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

DEUTSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

FRANÇAIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

NEDERLANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

ESPAÑOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

ITALIANO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

PORTUGUÊS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

ΕΛΛΗΝΙΚΑ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Rätt till ändring av specifikationer utan avisering förbehålles.

Ret til ændring af specifikationer uden varsel forbeholdes.

Rett til å endre spesifikasjoner uten varsel forbeholdes.

Oikeudet muutoksiin pidätetään.

Rights reserved to alter specifications without notice.

Änderungen vorbehalten.

Sous réserve de modifications sans avis préalable.

Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.

Reservado el derecho de cambiar las especificaciones sin previo aviso.

Ci riserviamo il diritto di variare le specifiche senza preavviso.

Reservamo-nos o direito de alterar as especificações sem aviso prévio.

∆ιατηρείται το δικαίωµα τρο ο οίησης ροδιαγραφών Χωρίς ροειδο οίηση.

- 75 -

1 DIRECTIVE........................................................................................ 76

2 SAFETY............................................................................................. 76

3 INTRODUCTION ............................................................................... 77

3.1 Generally...................................................................................................... 77

3.2 Delivery list................................................................................................... 77

3.3 Technical Data............................................................................................. 78

4 INSTALLATION................................................................................. 79

4.1 Generally...................................................................................................... 79

4.2 Location and Connection ............................................................................. 79

5 OPERATION...................................................................................... 80

5.1 Generally...................................................................................................... 80

5.2 Control installations and connections........................................................... 80

5.3 Remote control............................................................................................. 80

5.4 Overheating protection................................................................................. 81

5.5 Control Panel ............................................................................................... 81

5.6 Electrode welding (MMA)............................................................................. 86

5.7 TIG welding.................................................................................................. 87

5.8 Forced interruption....................................................................................... 91

6 MAINTENANCE ................................................................................ 92

6.1 Generally...................................................................................................... 92

6.2 Control and cleaning.................................................................................... 92

7 ACCESSORIES................................................................................. 92

8 ORDERING OF SPARE PARTS....................................................... 92

DIAGRAM ............................................................................................221

LIST OF COMPONENTS.....................................................................222

SPARE PARTS LIST ...........................................................................224

- 76 -

1 DIRECTIVE

CERTIFICATE OF PERMISSION

Esab Welding Equipment AB, 695 81 Laxå, Sweden, hereby declares under its sole

reponsability that the DTG 405 welding power source starting with serial number

917 928 001 complies with Standard EN 60974-1 in accordance with the requirements of

Directive 73/23/EWG Supplements 93/68/EWG.

Laxå 1999-07-09

Anders Birgersson

Managing Director

Esab Welding Equipment AB

695 81 LAXÅ

SWEDEN Tel: +46 584 81000 Fax: +46 584 411924

2SAFETY

Users of ESAB welding equipments are responsible for ensuring that all persons working directly with the

machine or standing in its vicinity are complying with all valid safety requirements.

The Safety requirements have to be in accordance with those for the particular welding equipment.

In addition to the Standard workplace instructions, the following directives should be observed

The operating of the equipment must be performed by trained personnel who are well-acquainted with its

functions.

Inadequate use of the equipment may create dangerous situations for the operator or cause damage to the

equipment.

1. The operator of the welding machine must be well-acquainted with:

•the handling

•the functions

•the valid safety instructions

•the welds.

2. The operator must ensure:

•that no unauthorized persons are situated in the working area while switching on the device.

•that all persons near the ignited arc are wearing adequate protection equipment.

3. The workplace should be:

•adequate for any need

•free of draught.

4. Personal protection equipment:

•Do always wear the corresponding personal protection equipment such as for example safety

glasses, fireproof clothing and protection gloves.

•Do not wear loose-fitting objects such as belts, bracelets, rings etc., which could get caught or

cause burns.

5. Miscellanous:

•Ensure that the corresponding return conduction is well connected.

•Works on high voltage equipment must only be done by trained personnel.

•Appropriate fire extinguishers must be clearly visible and easily accessible.

•Greasing and maintenance of the welding equipment must not be performed while operating.

- 77 -

3 INTRODUCTION

CAUTION! All warranty undertakings of the supplier cease to apply if the

customer attempts to rectify any faults on the machine during the

warranty period.

3.1 Generally

The DTG 405 is a welding rectifier with inverter technology for TIG- and electrode

welding. Welding with direct current as well as with alternating current is possible.

Theinvertertechnologyhasadvantagessuchaslowpowerconsumption,lightweightand

small dimensions.

Advanced power electronics provide fast welding current control and high class welding

current properties.

3.2 Delivery list

DTG 405 is delivered with:

•5 m of powercable

•5 m of workpiece cable

•1.8 m of gas hose and 2 hose clamps.

ARC WELDING AND CUTTING CAN CAUSE INJURY TO YOURSELF AND OTHERS. TAKE

PRECAUTIONS WHEN WELDING. FOLLOW YOUR EMPLOYERS SAFETY PRACTICES WHICH

ARE BASED ON MANUFACTURERS HAZARD DATA.

ELECTRIC SHOCKS- Can kill.

• Install and earth the welding unit in accordance with the appropriate 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 workplace 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 extract fumes and gases 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 ear defenders or other hearing protection.

• Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

WARNING

READ AND UNDERSTAND THE OPERATING MANUAL BEFORE INSTALLING OR OPERATING.

- 78 -

3.3 Technical Data

Relative duty cycle

The relative duty cycle shows the time in percent of a period of ten minutes in which one

could weld with a given current intensity without overloading the welding power source.

Application

The sign signifies that the welding current source is constructed for working in rooms

with raised electrical endangering.

Enclosure

The IP code indicates the enclosure, i. e. the degree of protection against penetration by

solid objects and water. Devices with the sign IP 23 is designed for operating outside as

well as for working indoors.

DTG 405

Welding range 3-400 A

Welding range electrode 3-400 A

Open-circuit voltage DC/AC 90 / <48 V

Current setting continuous

ED 100% 236 A

ED 60% 305 A

ED 35% 400 A

Electrode diameter 6 mm

Mains voltage 400 V

Max. power consumption S1 16.1 kVA

Power consumption S1 (100%) 7.5 kVA

Max. current consumption I1 23.3 A

Power factor 0.89 cos ϕ

Mains safeguarding 25 A/tr.

Mains connection power 4x4 qmm

Mains connector type CEE32

Enclosure type (IEC 529) IP23

Cooling AF

Dimensions 910x642x835 mm

Weight 116 kg

- 79 -

4 INSTALLATION

4.1 Generally

The installation must be done by a specialist.

4.2 Location and Connection

To reduce the voltage drop when using a long cable, it is advisable to select cable with

larger cross section.

•Locate the welding power source so that both the inlet and outlet vents for air cooling

are free from obstruction.

•Connect protective gas

•Connect TIG torch and return cable, alternative welding cable and return cable of the

electrode holder (see fig. page 80).

•Make sure that the welding power source is connected to the correct mains voltage

and is appropriately protected. Protective earthing in accordance with applicable

instructions should be ensured.

The rating plate with the connection dates are located on the back of the welding

power source .

Now the machine is ready for welding.

WARNING

This product is intended for industrial use. In a domestic environment this product

may cause radio interference. It is the user responsability to take adequate

precautions.

Mains voltage 400 V ± 10% 3~

Mains frequency 50-60 Hz

Fuse, slow-blow 25 A

Mains cable area 4x4 mm2

Welding cable area 50 mm2

- 80 -

5 OPERATION

5.1 Generally

Generaly safety instructions for the operation of the welding device are found on page 76.

Read the instructions before using the welding device.

5.2 Control installations and connections

Caution! The Positions F and G are omitted in versions with a central connection.

5.3 Remote control

The welding current during the TIG- and electrode welding can be adjusted using the

remote regulator.

With the remote regulator, any current between 3 A and the preset welding current I2 of

the unit can be selected.

AMains switch FTIG torch control cable connection

BCooling water-return (red) GGas connection for TIG torch

CCooling water-outlet (blue) HRemote control input

DBayonet-connection of the TIG torch IWelding current socket positive terminal

EWelding current socket negative termi-

nal JTIG torch central connection

- 81 -

5.4 Overheating protection

•An integrated thermal cut-out in the welding device protects the equipment from

overheating.

•The welding process is interrupted and the fault display (16) indicates error "4" .

•The equipment must be left in that condition to cool with the main switch left in the on

position and the cooling fans running.

CAUTION! When the error indicator "4" disappears, the position "Electrode" has to be

set to the open circuit voltage on the electrode; on position "TIG" the

welding device can now be started with the torch button. After cooling, the

device is reconnected automatically.

Care must be takento ensure that the electrode does not touch the welding

table, the workpiece or any other electrical conducting object during the

cooling phase of the power source in order to prevent unintentional arc igni-

tion when switching it on again.

An unintentionally ignited arc may damage the electrode holder, the

workpiece or the equipment.

5.5 Control Panel

1 Rotary switch,

spot time This rotary switch allows the duration of the spot time to be set to

values in the range from 0.1 to 10 s.

2 Operation

mode selector •Electrode welding with rod electrodes.

•TIG spot welding

•TIG four-step welding

•TIG two-step welding

3 LED, external

current

selection

LED illuminates, when the foot operated or hand operated remote

controls are connected and are controlling the welding current.

4LED,mains The greenLED illuminates when the device isconnected to the mains

and the mains switch is activated.

- 82 -

5 LED, welding LED illuminates when voltage isapplied to the welding current socket.

In the TIG operation mode, after activating the torch button whereas in

the electrode operation mode, this occurs after selecting electrode

welding.

6LED,

protective gas

LED illuminates when the solenoid valve is open and the protective

gas can flow. After switching the device on, the hose bundle is

automatically purged with protective gas.

7 LED, ramp up LED lights in the ramp up phase (Up-Slope).

8 Rotary switch,

ramp up Sets the rate at which the current ramps up from the ignition current I1

to the welding current I2. Turning direction anticlockwise decreases

the ramp rate.

9 Welding cur-

rent 7 segment

display

Displays the value of the welding current of the current function.

10 Rotary switch,

I4 Sets the current I4 during pulsed operation.

11 LED, I4 active I4 active. During pulsed operation: Toggles between the two displays

I4 and I2 with fixed pulse frequency.

12 LED,

ramp down Displays the ramp down phase (Down-Slope).

13 Rotary switch,

ramp down Sets the rate at which the welding current I2 ramps down to the

drop-off current I3 at the end of throat. The ramp down prevents

cratering.

14 Button, gas

test In order to manually purge the hose bundle with protective gas.

Pressing this button opens the gas valve without applying a welding

voltage to the electrode.

During pulsed operation: When activating the button gas test, the

display (10) switches to the I4 value.

15 Display,error

code Display of possible error messages.

16 LED, fault LED flashes if a fault condition occurs in the device. The error

message appears in the error display.

17 Rotary switch,

gas post-flow

time

Sets the gas post-flow time after finishing welding to protect the

weldpool. The time can be set from approximately 0.2 to 30s.

18 Rotary switch,

AC frequency Continuous setting of the AC frequency from 50 Hz up to 200 Hz.

19 LED, final

current I3 LED illuminates when the final current I3 is active.

20 Rotary switch,

AC balance If the rotary switch is set to the middle position, the positive and the

negative half cycles are equal for AC welding.

This rotary switch is deactivated, when welding using DC current (DC

operation).

21 Welding cur-

rent selector •DC with lift arc ignition

•DC with HF ignition

•Square AC with HF ignition

•Sinusoidal AC with HF ignition

22 LED, I1 LED illuminates, when the ignition current I1 is active.

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