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ESAB Miniarc 150 Instruction Manual
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ESAB Miniarc 150 Instruction Manual

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Miniarc 150
Instruction Manual
F15-725
02 / 2006

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Summary of Contents for ESAB Miniarc 150

  • Page 1 Miniarc 150 Instruction Manual F15-725 02 / 2006...
  • Page 2 Be sure this information reaches the operator. You can get extra copies through Your supplier. These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of opera- tion and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment. USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Table of Contents SECTION ..........................Page Safety ............................3 SECTION 1 Description ........................9 SECTION 2 Installation ........................10 SECTION 3 Operation ........................ 12 SECTION 4 Maintenance ......................... 31 SECTION 5 Troubleshooting ......................32 SECTION 6 Replacement Parts ........................34...
  • Page 4 TABLE OF CONTENTS...

  • Page 5: Safety

    SAFETY PRECAUTIONS WARNING: hese Safety Precautions are for your 6. After completing operations, inspect the work area to make protection. They summarize precautionary infor- certain there are no hot sparks or hot metal which could cause a later fire. Use fire watchers when necessary. mation from the references listed in Additional 7.
  • Page 6 troubleshooting, and maintenance work. Do FUMES AND GASES -- Fumes and gases, not perform any electrical work unless you are can c ause d iscomfort o r h arm, p articularly qualified to perform such work. in confined spaces. Do not breathe fumes Before performing any maintenance work and gases. Shielding gases can cause inside a power source, disconnect the power asphyxiation. Therefore: source from the incoming electrical power.
  • Page 7 PRECAUCION DE SEGURIDAD No use el equipo fuera de su rango de operación. Por ejemplo, el ADVERTENCIA: Estas Precauciones de Seguridad son calor causado por cable sobrecarga en los cables de soldar pueden para su protección. Ellas hacen resumen de información ocasionar un fuego. proveniente de las referencias listadas en la sección 6.
  • Page 8 MANTENIMIENTO DEL EQUIPO -- Equipo de- HUMO Y GASES -- El humo y los gases, fectuoso o mal mantenido puede causar daño pueden c ausar m alestar o d año, p articu- o muerte. Por lo tanto: larmente e n e spacios s in v entilación. N o inhale e l humo o g ases. E l gas de p rotec- 1. Siempre tenga personal cualificado para efectuar l a ción puede causar falta de oxígeno.
  • Page 9 PRéCAUTIONS DE SéCURITé a. éloigner suffisamment tous les matériaux combustibles AVERTISSEMENT: Ces règles de sécurité ont pour objet d’ as- du secteur où l’on exécute des soudures ou des coupes surer votre protection. Veillez à lire et à observer les précau- à...
  • Page 10 à l’amélioration de la ventilation. Ne poursuivez pas cautions and Safe Practices for Arc Welding, Cutting and l’opération entreprise si le malaise persiste. Gouging” publié par ESAB. Nous conseillons également d. Certaines commandes comportent des canalisations de consulter les publications sui-vantes, tenues à votre où...

  • Page 11: Description

    SECTION 1 DESCRIPTION INTRODUCTION The Miniarc 10 APS is a small, portable, inverter based power source for MMA or TIG welding using the scratch start method. The unit provides up to 10A welding current and operates from either 230V or 11V single phase AC electricity supplies.
  • Page 12 SECTION 1 DESCRIPTION...

  • Page 13: Installation

    INSTALLATION INSTALLATION A. ESAB 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 minimized.
  • Page 14 SECTION 2 INSTALLATION Main Extension Cables Care must be taken when supplying the unit via long power extension cables. On 230V supplies the recommended cable is a 10AWG, 3-conductor. On 11V supplies extension cables are not recommended. Siting the unit Position the unit to give good all-round ventilation. Do not block the air inlet on the rear panel or the front or side panel louvers.

  • Page 15: Operation

    SECTION 3 OPERATION THERMAL OVERLOAD INDICATOR Indicates ‘overload’ condition. If the lamp lights, leave the unit switched on with the fan running and allow to cool. Reset is automatic after the unit cools. WELDING CURRENT CONTROL Over-Temperature Indicator Output current can be set in the range 10 to 10A Power ON/OFF Switch...
  • Page 16 SECTION 3 OPERATION (b) Carry on scraping the electrode across the surface of the workpiece until the arc is almost continuous, then feed the electrode into the hot pool of molten metal keeping the electrode at approximately 6-80° to the workpiece. If the electrodes ‘freezes’...
  • Page 17 SECTION 3 OPERATION TIG WELDING Preparation Read again the Safety Notes at the front of this manual Select Lift Tig in the Process Selector Switch Connect the work return lead to the positive socket. Connect the torch power lead to the negative ‘work’ socket. Fit the regulator and gas flow meter to the gas cylinder and, using a cylinder key, turn on the gas and adjust the gas flow for a 6 to 7. litres/minute (12-1cu.ft/hr.) indication on the flow meter.
  • Page 18 SECTION 3 OPERATION Technique Set the output current control as required. Once the arc is struck the current can be lowered as required. Switch on the unit Switch on the gas flow to ‘purge’ the gas lines, adjust the gas flow for a 12-1 cu.ft/hr (6-7. ltrs/per min.) indication on the flow meter.
  • Page 19 SECTION 3 OPERATION TIG ELECTRODES In order to obtain the optimum arc striking performance with the Miniarc 10 APS it is recommended that 2% Thori- ated tungstens are exclusively used (red tip). Maximum Electrode Ratings d.c. Electrode Dia. Current Range .00” A -70A 1/16” 0A - 10A Figure 3.5 Shielding Gas To prevent oxidation, always purge the argon hose before welding and maintain the argon flow until the tungsten has...
  • Page 20 SECTION 3 OPERATION Principles of Shielded Metal Arc Welding GENERAL Shielded Metal-Arc welding depends upon the fundamental fact that when one side of the secondary welding circuit is at- tached to a piece of steel and the other side of the circuit is connected to an electrode, an arc will be established when the electrode touches the steel.
  • Page 21 SECTION 3 OPERATION positioned horizontally, vertically and overhead as shown in Figure 3.8, 3.9, and 3.10 respectivily. It must be realized at the very beginning that welding in these positions is difficult and will require constant practice to develop skill. Generally, under these conditions it is helpful to reduce the current from the value used on welding in the flat position.
  • Page 22 SECTION 3 OPERATION Figure 3.12 Arc Initiation - Scratch Start When the electrode touches the work, the welding starts. If held in this position, the electrode would freeze or weld itself to the work. To overcome this, the electrode should be slightly withdrawn from the work immediately after contact has been made.
  • Page 23 SECTION 3 OPERATION Figure 3.14 Proper Weld Bead Probably the first attempts in the practice will fail short of the results shown. Too long an arc will be held or the travel speed will vary from slow to fast and the welds will look as illustrated in Figure 3.1 showing a cross section through a poor weld- ing bead.
  • Page 24 SECTION 3 OPERATION Continue practicing until uniform beads as shown in Figure 3.1 can be produced. A good method of practicing is to deposit a series of beads, one next to the other until the plate is covered. The slag must be thoroughly removed between each pass. Then deposit another series of beads at right angles to the first, thus holding up the plate to a greater thickness.
  • Page 25 SECTION 3 OPERATION In making weld beads previously described, it was probably noted that depositing weld metal on one side of the plate, caused it to curl up towards the weld; this is called distortion and will almost always be found when heat is applied locally to a metal plate.
  • Page 26 SECTION 3 OPERATION When making practice butt welds it is wise to check the results occasionally. Where elaborate testing equipment is not available, this may be done with a hammer and vise. CAUTION SHOULD BE OBSERVED IN HANDLING WELDED PIECES OF METAL, SINCE WELD HEAT ABSORBED BY THE METAL IS INTENSE AND CAN CAUSE SERIOUS BURNS. Grip a short, welded piece with the weld just above the jaws of the vise. Hammer it in a direction that tends to open the bottom, root side of the weld, in the manner shown in Figure 3.19.
  • Page 27 SECTION 3 OPERATION Figure 3.21 Lap Joint Considering the tee joint first, it will be seen immediately that the position of the pieces requires a different method of electrode manipulation than for a butt weld. The method of holding the electrode for butt welds will not be satisfactory. To deposit a single pass fillet weld, hold the electrode as shown in Figure 3.22.
  • Page 28 SECTION 3 OPERATION Figure 3.24 Tee Joint Fillet Weld Weave Patterns The lap joint, while involving the same fundamental weld type, the fillet, has metal distributed differently and therefore requires still another technique. The details of the application are given in Figure 3.2, for a single pass weld. For a two pass weld, Figure 3.26 provides the details.
  • Page 29 SECTION 3 OPERATION As in the case of welding in the flat position, it is best to start practicing by first running weld beads in the various positions. Then as proficiency is gained on these operations, practice may be continued on butt and fillet welds (tee and lap joints) in these positions.
  • Page 30 SECTION 3 OPERATION Figure 3.30 - Weave Pattern Since single weld beads are of limited value, weaving weld beads must be practiced on butt welds in the vertical and horizontal positions. Figure 3.31 provides information suitable for a single pass vertical butt weld or the first pass of a multiple layer deposit. Two methods of depositing the subsequent layers are given in Figure3.32.
  • Page 31 SECTION 3 OPERATION For fillet welds on tee and lap joints the technique is shown in Figure 3.3. When depositing a multilayer fillet weld, the same method would be used to deposit the first layer on both lap and tee joints. For depositing subsequent layers on tee joints two means are used and are shown in Figure 3.36.
  • Page 32 SECTION 3 OPERATION Figure 3.36 Multilayer Deposit - Lap Joint Figure 3.37 Multilayer Deposir - Lap Joint Figure 3.38 Electrode Position & Weave Pattern Welding in the overhead position is the final problem to master. Again proceed through the steps of making weld beads, the making of butt welds and finally the making of fillet welds. For overhead welding, the electrode position, Figure 3.38, will prove helpful.
  • Page 33 SECTION 3 OPERATION Figure 3.41 Multilayer Deposit - Overhead Butt Weld Figure 3.42 Overhead Tee Weld - Single Pass Figure 3.43 Multilayer Deposit - Overhead Tee Weld CONCLUSION It may be appreciated that no printed instruction can impart to the beginner all the skills necessary for successful welding. Personal instruction by an experienced welding operator is the best means for accomplishing this end. Therefore, an effort should be made to secure some facility for instruction and practice under competent supervision.
  • Page 34 SECTION 3 OPERATION...

  • Page 35: Maintenance

    SECTION 4 MAINTENANCE MAINTENANCE WARNING MAINTENANCE INVOLVING THE REMOVAL OF THE OUTER COVER MUST ONLY BE UNDERTAKEN BY QUALI- FIED OR SUITABLY TRAINED PERSONNEL. Switch off and disconnect the unit from the main supply before under-taking any maintenance tasks. Daily (Operator task) Check all welding and electrical cables for signs of cracking or general deterioration. Check that all electrical (and gas) connections are in good physical condition.
  • Page 36 SECTION 4 MAINTENANCE...

  • Page 37: Troubleshooting

    SECTION 5 TROUBLESHOOTING WELDING AND GENERAL FAULTS Fault Remedies Surface a) Insufficient shielding gas (TIG). a) Check shielding gas flow. porosity b) Bore of nozzle too small (TIG). b) Fit larger ceramic nozzle. c) Surplus degreasing agent (MMA & TIG) c) Remove degreasing agent and dry. d) Arc too long (MMA and TIG).

  • Page 39: Replacement Parts

    Be sure to indicate any special shipping instructions when ordering replacement parts. To order parts by phone, contact ESAB at 1-83-66-0. Orders may also be faxed to 1-800-63-78. Be sure to indicate any special shipping instructions when ordering replacement parts.
  • Page 40 SECTION 6 REPLACEMENT PARTS ITEM QTY. PART CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL 0800331 Plastic Carrying Case...
  • Page 41 SECTION 6 REPLACEMENT PARTS ITEM QTY. PART CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL 0800277 Power Switch 0800273 Knobs 08002707 Dinse Socket 0800339 Circuit Breaker...
  • Page 42 SECTION 6 REPLACEMENT PARTS 1,  ITEM QTY. PART CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL 08002738 0800276 EMC Filter 08003339 Inverter pcb ass’y PCB2 0800331 Voltage autoswitch PCB PCB1 08002739 Grid, Fan...
  • Page 43 SECTION 6 REPLACEMENT PARTS ITEM QTY. PART CIRCUIT NO. REQ. NO. DESCRIPTION SYMBOL 0800330 Control Transformer 0800330 Control P/C Board PCB3...
  • Page 44 Notes...
  • Page 45 Notes...
  • Page 46 Notes...
  • Page 47 Revision History 07 / 200 - Updated part numbers on Pages 38, 1, 2 and 3 to reflect latest Florence numbers to be used for ordering. Added Page 0 to illustrate plastic carrying case. 02 / 2006 - Updated entire manual format and replaced Schematic with latest revision.
  • Page 48 IF YOU DO NOT KNOW WHOM TO CALL Telephone: (800) ESAB-123 Fax: (83) 66-2 Hours: 7:30 AM to :00 PM EST visit us on the web at http://www.esabna.com The ESAB web site offers Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator...