CEA MATRIX 420 E, MATRIX 4200 E, MATRIX 420 E-MG, MATRIX 4200 E-MG Operator's Manual

EN
Operator’s manual
READ CAREFULLY
420 - 4200
MATRIX E • E-MG
CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A.
C.so E. Filiberto, 27 - 23900 Lecco - Italy
Cas. Post. (P.O.BOX) 205
E-mail: cea@ceaweld.com - web: www.ceaweld.com
1020HC38A-EN-07/2017 SN - JG xxxxxx
EN
ENGLISH
Introduction 2
Description 2
Technical data 3
Usage limits (IEC 60974-1) 3
How to lift up the machine 3
Open the packaging 3
Installation 3
Connection to the electrical supply 3
Instructions for use 4
Electrode welding (MMA) 4
TIG welding 5
Maintenance 5
Optional 6
The pointing out of any difficulties
and their elimination 6
Procedure for cover assembly and disassembly 6
Digital interface PCB replacement 6
Meaning of graphic symbols on machine 7
Key to the electrical diagram 7
Colour key 7
Wiring diagram 8
Introduction
Thank you for buying our product. In order to get the best performance out of the plant and ensure the maximum lifespan of its parts, the use and maintenance instructions contained in this manual must be read and strictly complied with, as well as the safety instructions contained in the relevant folder. If repairs to the plant are required, we recommend that our clients contact our service centre work­shops, as they have the necessary equipment and personnel that are specifically trained and constantly updated. All our machines and equipment are constantly developed and so changes may be made in terms of their construction and features.
Description
Powerful, compact, and light-weight - thanks to the innova­tive digital welding control the MATRIX 420-4200 units are the highest performance and most technically advanced electrode welding generators you can find. Built according to the very latest IGBT based inverter tech­nology, these DC power sources thanks to their excellent arc characteristics, are recommended for highest standard appli­cations with any electrode. MATRIX 420-4200 units guarantee absolute stability of welding parameters and thanks to their “characteristic dynamic speed” they are ideal for quality welding particularly difficult jobs using basic and cellulosic electrodes. The MATRIX 420-4200 units can also be used for TIG welding with a “Lift” type ignition.
FEATURES
• Innovative and compact design.
• Reduced weight and size, easy-to-carry.
• Metallic main structure with shock-proof plastic front panel.
• Controls protected against accidental blows.
• Robust handle integrated into the chassis. Slanting front panel with wide range of visibility from all an-
• gles to facilitate reading and adjusting parameters. Digital ammeters and voltmeters are standard fittings, with
• pre-setting of welding current and saving of the latest value (Hold function).
• Digital control of all welding parameters. Possibility of saving the welding parameters (99 automatic
• welding points - JOBS).
• Self-diagnosis device. Exceptional welding characteristics for all types of electrode,
• including cellulosic.
• MMA welding:
- “Arc Force” adjustable to select the best dynamic charac­teristics for the welding arc. “Hot Start” adjustable to improve ignition with particularly
­difficult electrodes.
- Anti-sticking function to avoid the electrodes sticking.
• TIG welding:
- TIG welding using the innovative “Lift” type thermally con­trolled ignition (TCS). Ignition comes about precisely and quickly, reducing the inclusions of tungsten to a minimum and doing away with incisions into the workpiece to be welded. A synergic SWS (Smart welding stop) system that reduces
­electrode consumption and avoids oxidation of the weld­ed joint.
• Overheating thermostatic protection. Automatic compensation for mains voltage fluctuations with-
• in +15% -20%.
• Safety barrier against excess voltage from mains. The VRD (Voltage Reduction Device) can be activated, which
• reduces voltages to below 12 V, which means that the weld8 ing machine can be used in ambient conditions in which there is a high electrical risk, thereby providing maximum opera­tor safety. An “Energy Saving” function that only activates ventilation
• of the generator when necessary, making significant energy saving possible and reducing maintenance, due to the small quantity of dust and pollutants that are taken in. IP 23 S protection class and dust-proof electronic compo-
• nents, thanks to the innovative “Tunnel” fan cooling system, allow operation in the toughest work environments. Can be connected to motor-powered generators of adequate
• capacity providing high dependability - 30 kVA (MATRIX 420­4200 E-MG).
• Useable with power supply cables more than 100 m long.
• Reduced energy consumption.
2
• This generator also conforms to all the standards and direc­tives in force in the European Community.
Technical data
The general technical data of the system are summarized in table 1.
Table 1
Model
Three-phase input 50/60 Hz V 400 +15% -20% Power supply: Z Input power @ I Delayed fuse (I
Power factor / cosφ 0,95 / 0,99
Efficiency degree η 0,88 Open circuit voltage V 100 Current range A 5 ÷ 420 Duty cycle @ 100% (40°C) A 270 Duty cycle @ 60% (40°C) A 340 Duty cycle @ 40% (40°C) A 420 Usable electrodes mm 1,6 ÷ 6,0
Standards
Protection class IP 23 S Insulation class H Dimensions Weight kg 20
WARNING: This equipment complies with EN/IEC 61000-3-12 pro- vided that the maximum permissible system impedance Z
than or equal to 0,034 Ω at the interface point between the user’s sup­ply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution net­work operator if necessary, that the equipment is connected only to a
supply with maximum permissible system impedance Z
or equal to 0,034 Ω.
This system, tested according to EN/IEC 61000-3-3, meets the re­quirements of EN/IEC 61000-3-11.
max
Max kVA 17,4
2
@ 100%) A 16
2
MATRIX 420-4200
E / E-MG
Ω 0,034
IEC 60974-1
IEC 60974-10
mm 500 - 425 - 220
is less
max
less than
max
Usage limits (IEC 60974-1)
NOTE: These hoisting and transportation devices conform to
European standards. Do not use other hoisting and transpor­tation systems.
Open the packaging
The system essentially consists of:
MATRIX 420-4200 E or E-MG weld unit.
• Welding cables or RTA TIG torch (optional).
• Trolley for transportation (optional).
• Protective roll bar (optional). Upon receiving the system:
Remove the welding generator and all relevant accessories-
• components from their packaging. Check that the weld machine is in good condition, if not report
• any problems immediately to the seller-distributor.
• Make sure all ventilation grilles are open and that no foreign bodies are blocking the air circulation.
Installation
The installation site for the system must be carefully chosen in order to ensure its satisfactory and safe use. The user is re­sponsible for the installation and use of the system in accord­ance with the producer’s instructions contained in this manual. Before installing the system the user must take into consider­ation the potential electromagnetic problems in the work area. In particular, we suggest that you should avoid installing the system close to:
• Signalling, control and telephone cables.
• Radio and television transmitters and receivers.
• Computers and control and measurement instruments.
• Security and protection instruments.
Persons fitted with pace-makers, hearing aids and similar equipment must consult their doctor before going near a ma­chine in operation. The environment in which the equipment is installed must be suitable for the casing’s protection level. This system is cooled by means of the forced circulation of air, and must therefore be placed in such a way that the air may be easily sucked in and expelled through the apertures made in the frame. The welding unit is characterised by the following levels:
• Protection level IP 23 S indicates that the equipment can be used both indoors and outdoors. Use class “S” means that the equipment can be used in con
• ditions subject to heightened electrical shock.
-
The use of a welder is typically discontinuous, in that it is made up of effective work periods (welding) and rest periods (for the positioning of parts, the replacement of wire and underflush ing operations etc. This welder is dimensioned to supply a I2 max nominal current in complete safety for a period of work of 40% of the total usage time. The regulations in force establish the total usage time to be 10 minutes. The work cycle is con­sidered to be 40% of this period of time. If the permitted work cycle time is exceeded, an overheat cut-off occurs to protect the components around the welder from dangerous overheat­ing. Activation of thermal protection is signaled by “t° C” flash­ing on control panel display (for further information see the MX control panel manual). After several minutes the overheat cut­off rearms automatically and the welder is ready for use again.
How to lift up the machine
Strap the hoisting belts around the machine and lift it up care­fully and safely, slinging it from the bottom up. The weld machine has a strong handle all in one with the frame, used for transporting the machine manually only.
Connection to the electrical supply
-
Connection of the machine to the user line (electrical cur­rent) must be performed by qualified personnel. Before connecting the welding machine to the mains pow­er supply, make sure that rated voltage and frequency cor­respond to those provided by the mains power supply and that the welding machine’s power switch is turned to “O”.
Use the welder’s own plug to connect it up to the main pow­er supply. Proceed as follows if you have to replace the plug:
3 conducting wires are needed for connecting the machine
• to the supply The fourth, which is YELLOW GREEN in colour is used for
• making the “GROUND” connection.
Connect a suitable load of normalised plug (3p+t) to the power cable and provide for an electrical socket complete with fuses or an automatic switch. The ground terminal must be connected to the ground conducting wire (YEL­LOW-GREEN) of the supply.
3
Table 2 shows the capacity values that are recommended for fuses in the line with delays.
Table 2
m
mm
2
2
MATRIX 420-4200
E / E-MG
4
2,5
50
Model
Input power @ I Delayed fuse (I Duty cycle @ 40% (40°C) A 420 Mains cable
Length Section
Ground cable Section mm
Max kVA 17,4
2
@ 100%) A 16
2
NOTE: Any extensions to the power cable must be of a suita­ble diameter, and absolutely not of a smaller diameter than the
special cable supplied with the machine.
Instructions for use
COMMAND AND CONTROL UNITS (Fig. A)
Pos. 1 MX command and control panel. For detailed infor-
mation on the control panel, see the instruction man­ual enclosed.
Pos. 2 6 pole remote control connector. Pos. 3 Positive pole quick connection. Pos. 4 Negative pole quick connection. Pos. 5 Power supply switch. In the “O” position the welder
is off.
Pos. 6 Mains cable.
1
2
4
3
Electrode welding (MMA)
Electrode welding is used for welding most metals (various types of steels, etc.) using rutilic, basic, and cellulosic elec trodes with diameters from 1.6 mm to 6.0 mm.
1) Connecting the welding cables (Fig. B): Disconnect the machine from the mains power supply and
connect the welding cables to the output terminals (Positive and Negative) of the welding machine, attaching them to the clamp and ground with the polarity specified for the type of electrode being used (Fig.B). Always follow the electrode manufacturer’s instructions. The welding cables must be as short as possible, they must be near to one another, po­sitioned at or near floor level. Do not touch the electrode clamp and the ground clamp simultaneously.
2) Switch the welding machine on by moving the power sup-
ply switch to I (Pos. 5, Fig. A).
3) Make the adjustments and select the parameters on the control panel (for further information see the MX control panel manual).
4) Carry out welding by moving the torch to the workpiece. Strike the arc (press the electrode quickly against the met­al and then lift it) to melt the electrode, the coating of which forms a protective residue. Then continue welding by mov­ing the electrode from left to right, inclining it by about 60° compared with the metal in relation to the direction of weld­ing.
PART TO BE WELDED
The part to be welded must always be connected to ground in order to reduce electromagnetic emission. Much attention must be afforded so that the ground connection of the part to be welded does not increase the risk of accident to the user or the risk of damage to other electric equipment. When it is nec­essary to connect the part to be welded to ground, you should make a direct connection between the part and the ground shaft. In those countries in which such a connection is not al­lowed, connect the part to be welded to ground using suitable capacitors, in compliance with the national regulations.
-
FIG. A
WELDING THICKNESS (mm) Ø ELECTRODE (mm)
1,5 ÷ 3
3 ÷ 5
5 ÷ 12
≥ 12
Ø ELECTRODE (mm) CURRENT (A)
1,6
2 2,5 3,2
4
5
6
30 ÷ 60
40 ÷ 75 60 ÷ 110 95 ÷ 140
140 ÷ 190 190 ÷ 240 220 ÷ 330
5
6
Table 3
2 2,5 3,2
4
Table 4
4
WELDING PARAMETERS
Table 3 shows some general indications for the choice of elec­trode, based on the thickness of the parts to be welded. The values of current to use are shown in the table with the respec­tive electrodes for the welding of common steels and low-grade alloys. These data have no absolute value and are indicative data only. For a precise choice follow the instructions provided by the electrode manufacturer. The current to be used depends on the welding positions and the type of joint, and it increases according to the thickness and dimensions of the part. The current intensity to be used for the different types of weld­ing, within the field of regulation shown in table 4 is:
• High for plane, frontal plane and vertical upwards welding.
• Medium for overhead welding. Low for vertical downwards welding and for joining small pre-
• heated pieces.
A fairly approximate indication of the average current to use in the welding of electrodes for ordinary steel is given by the fol­lowing formula:
I = 50 × (Øe - 1)
Where: I = intensity of the welding current Øe = electrode diameter
Example: For electrode diameter 4 mm
I = 50 × (4 - 1) = 50 × 3 = 150A
TIG welding
TIG welding melts the metal of the workpiece, using an arc struck by a tungsten electrode. The fusion bath and the elec­trode are protected by gas (Argon). This type of welding is used to weld thin sheet metal or when elevated quality is required.
1) Connecting the welding cables (Fig. C): Connect one end of the gas hose to the gas connecter
• on the TIG torch and the other end to the Argon cylin­der and open it.
• With the machine switched off:
Connect the ground cable to the snap-on connector
­marked + (positive). Connect the relative ground clamp to the workpiece or
­to the workpiece support in an area free of rust, paint, grease, etc.. Connect the TIG torch power cable to the snap-on con
­nector marked - (negative).
2) Switch the welding machine on by moving the power sup-
ply switch to I (Pos. 5, Fig. A).
3) Make the adjustments and select the parameters on the control panel (for further information see the MX control panel manual).
4) Open the gas cylinder and regulate the flow by adjusting the valve on the TIG torch by hand.
5) Ignite the electric arc by contact, using a decisive, quick movement at the welding current set (“Lift” type ignition ­Fig. D).
To end welding:
Lift the torch slowly, at a certain point the welding current
decreases, and then stop. The welding machine follows an automatic down slope
along with extinguishing of the arc.
6) When you have finished welding remember to shut the valve on the torch and the gas cylinder.
-
FIG. B
Maintenance
ATTENTION: Before carrying out any inspection of the inside
of the generator, disconnect the system from the supply.
SPARE PARTS
Original spare parts have been specially designed for our equipment. The use of non-original spare parts may cause variations in performance or reduce the foreseen level of safety.
2000HA802000HA81
We decline all responsibility for the use of non-original spare parts.
FIG. C
5
FIG. D
2000HA86
GENERATOR
1
2
3
4
5
As these systems are completely static, proceed as follow:
Periodic removal of accumulated dirt and dust from the inside
• of the generator, using compressed air. Do not aim the air jet directly onto the electrical components, in order to avoid damaging them.
• Make periodical inspections in order to individuate worn ca­bles or loose connections that are the cause of overheating.
Optional
CD 6 manual remote control. When this accessory is activated the welding current can only be remote controlled (value adjustable from 5 to 420A), and this value will be shown on the welding machine’s display. The digital control unit of the generator is fitted with a control recognition device which allows it to identify which device is connected and take action accordingly. The remote control can be connected whether the welding machine is on or off.
NOTE: The MX control panel has a STAND-BY function that, when the remote control is on, switches off the inverter when
the minimum welding current value is reached (to reinstate normal, correct functioning of the machine, increase the weld­ing current value by rotating the remote control knob).
• External mechanical polarity inverter.
The pointing out of any difficulties
and their elimination
The supply line is attributed with the cause of the most com­mon difficulties. In the case of breakdown, proceed as follows:
1) Check the value of the supply voltage
2) Check that the power cable is perfectly connected to the
plug and the supply switch
3) Check that the power fuses are not burned out or loose
4) Check whether the following are defective:
• The switch that supplies the machine.
• The plug socket in the wall.
• The generator switch.
NOTE: Given the required technical skills necessary for the re­pair of the generator, in case of breakdown we advise you to
contact skilled personnel or our technical service department.
Procedure for cover assembly
and disassembly
Proceed as follows (Fig. E):
1) Unscrew the two screws fastening the handle.
2) Take off handle pulling it backwards.
3) Take off covering lid and unscrew the 3 screws fastening
the top.
4) Use both hands to push the top towards the front part free-
ing the back part.
5) Remove top by lifting with both hands.
Proceed vice versa for assembly.
Digital interface PCB replacement
• Unscrew the 4 screws fastening the front rack panel.
• Remove control dials.
• Extract wiring connectors from the digital interface PCB.
• Unscrew small supporting columns. Remove the digital interface PCB by lifting it out of its sup-
• ports. Proceed vice versa to assemble the new digital interface
• PCB.
FIG. E
6
Meaning of graphic symbols on machine
Power supply switch
System for use in environments with in­creased risk of electroshock
Product suitable for free circulation in the Eu­ropean Community
Dangerous voltage
Grounding
Positive pole snap-in connector
Negative pole snap-in connector
Remote control socket
Warning!
Before using the equipment you should care­fully read the instructions included in this man­ual
TIG welding
MMA welding
Special disposal
•1 •2 •3 •4 •5 •6 •7
3PH-EMC CCD Cp D1-2-3-4-5-6 IL L MIH
•8 •9 •10 •11 •12 •13 •14
MIL MV P1 P2 PD RP S-C4 LINK
•15 •16 •17 •18 •19 •20 •21
S-DOUBLER S-INT DIG S-INV TA TC TH2 TP
Key to the electrical diagram
•1 EMC filter •2 Remote control socket •3 Protection capacitor •4 Secund-
ary diodes •5 Power supply switch •6 Secondary inductor •7 Primary upper IGBT •8 Lower primary IGBT •9 Fan motor •10 Main primary transform­er (start) •11 Main primary transformer (end) •12 Remote current poten­tiometer •13 Primary rectifier •14 Capacitors PCB (MATRIX 420 E-MG)
•15 Booster board •16 Digital interface PCB •17 Inverter PCB •18 Auxilia-
ry transformer •19 Current transducer •20 Thermostat on the secondary heatsink •21 Transformer
Colour key
Ar Orange Az Sky Blue Bc White Bl Blue GV Yellow Green Mr Brown Nr Black Ro Pink Rs Red Vd Green Vl Violet
7
Wiring diagram
2101FA22
8
IT
Lista ricambi
LEGGERE ATTENTAMENTE
EN
FR
DE
ES
NL
PT
SV
Spare parts list
Liste pièce de rechange
Ersatzteilliste
Lista repuestos
Onderdelenlijst
Lista de peças de substituição
Reservdelslista
READ CAREFULLY
LIRE ATTENTIVEMENT
SORGFÄLTIG LESEN
LEER ATENTAMENTE
EERST GOED DOORLEZEN
LER ATENTEMENTE
LÄS NOGAS
FI
N
420 - 4200
EL
RU
MATRIX E • E-MG
Varaosaluettelo
Reservedelliste
Κατάλογος ανταλλακτικών
Список запасных частей
LUE HUOLELLISESTI
LES NØYE
ΔΙΑΒΑΣΤΕ ΠΡΟΣΕΚΤΙΚΑ
ПЕРЕД НАЧАЛОМ РАБОТЫ ВНИМАТЕЛЬНО ПРОЧТИТЕ ИНСТРУКЦИЮ
CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A.
C.so E. Filiberto, 27 - 23900 Lecco - Italy
Cas. Post. (P.O.BOX) 205
E-mail: cea@ceaweld.com - web: www.ceaweld.com
1
9
38
10
2
3
11
39
12
4
8
5
13
14
7
6
Pos.
1 434696 434696 Maniglia Handle 2 439360 439404 Pannello rack con adesivo "MATRIX" Rack panel with "MATRIX" sticker 3 438888 438888 Manopola senza indice Ø29mm Ø29mm Knob without index
4 352373 352373 Pannello frontale Front panel
5 403614 403614 Attacco rapido Quick connection 6 419050 419050 Connettore comando a distanza Remote Control Socket 7 467055 467055 Adesivo frontale Front sticker 8 420497 420497 Coperchio Cover
9 352419 352419 Coperchio pannello frontale Front panel cover 10 438710 438710 Manopola interruttore alimentazione Mains switch knob 11 352416 352416 Pannello posteriore Rear panel 12 427882 427882 Pressacavo Cable clamp 13 430757 430757 Ghiera pressacavo Cable clamp lock ring 14 235948 235948 Cavo alimentazione Mains cable
MATRIX
420
MATRIX
4200
Descrizione Description
2
15
23
17
16
18
19
20
2122
Pos.
15 449499 449499 Piastra superiore Upper plate 16 427667 427667 Filtro EMC EMC Filter 17 413541 413541 Cablaggio ausiliario Auxiliary wiring 18 455508 455508 Raddrizzatore primario Primary rectifier 19 486380 486380 Motore ventilatore Fan motor 20 466144 466144 Piastra supporto motore ventilatore Fan motor support plate 21 404935 404935 Basamento Base 22 286034 286034 IGBT primario Primary IGBT 23 352412 352412 Guida laterale Side guide
MATRIX
420
MATRIX
4200
Descrizione Description
3
24
2930313233
25
26
27
28
Pos.
24 435760 435760 Interruttore alimentazione Mains switch 25 481919 481919 Trasformatore ausiliario Auxiliary transformer 26 481407 481407 Trasformatore Transformer 27 481952 481952 Trasduttore di corrente Current transducer 28 413619 413619 Cablaggio trasduttore di corrente Current transducer wiring 29 418872 418872 Condensatore di protezione Protection capacitor 30 240231 240231 Induttore secondario Secondary inductor 31 478846 478846 Termostato su dissipatore secondario Thermostat on secondary heatsink 32 423236 423236 Diodo secondario Secondary diode 33 377087 377087 Scheda survoltore Doubler PCB
MATRIX
420
MATRIX
4200
Descrizione Description
4
36
34
35
38
39
37
Pos.
34 377089 377089 Scheda interfaccia digitale Digital Interface PCB 35 454150 454150 Encoder Encoder 36 240470 240470 Complessivo inverter primario Primary inverter assembly
37 377157 377157
38 352374 352374 Visiera pannello frontale Front rack transparent visor 39 468725 468725 Logo CEA pannello frontale Logo CEA sticker for front panel
MATRIX
420
MATRIX
4200
Descrizione Description
Scheda condensatori (solo per
Matrix 420-4200 E-MG)
Capacitors PCB (only for
Matrix 420-4200 E-MG)
5
IT
Ordinazione dei pezzi di ricambio
Per la richiesta di pezzi di ricambio indicare chiaramente:
1) Il numero di codice del particolare
2) Il tipo di impianto
3) La tensione e la frequenza che rileverete dalla targhetta dei dati posta sull’impianto
4) Il numero di matricola
PT
Encomenda das peças de reposição
Ao pedir as peças de substituição indique claramente:
1) O número de código da peça
2) O tipo de equipamento
3) A tensão e a frequência indicadas na la placa de dados do equipamento
4) O número de matrícula da própria máquina de soldar
ESEMPIO
N° 2 pezzi, codice n. 435760 - per l’impianto MATRIX 4200
E - 400 V - 50/60 Hz - Matricola n° ........................................
EN
Ordering spare parts
To ask for spare parts clearly state:
1) The code number of the piece
2) The type of device
3) The voltage and frequency read on the rating plate
4) The serial number of the same
EXAMPLE
N. 2 pieces code n. 435760 - for MATRIX 4200 E - 400 V -
50/60 Hz - Serial number .......................................................
FR
Commade des pièces de rechange
Pour commander des pièces de rechange indiquer clairement:
1) Le numéro de code de la pièce
2) Le type d’installation
3) La tension et la fréquence que vous trouverez sur la petite plaque de données placée sur l’installation
4) Le numéro de matricule de la même
EXEMPLE
N. 2 pièces code 435760 - pour l’installation MATRIX 4200 E -
400 V - 50/60 Hz - Matr. Numéro ....................................
DE
Bestellung Ersatzeile
Für die Anforderung von Ersatzteilen geben Sie bitte deutlich an:
1) Die Artikelnummer des Teiles
2) Den Anlagentyp
3) Die Spannung und Frequenz, die Sie auf dem Datenschild der Anlage finden
4) Die Seriennummer der Schweißmaschine
BEISPIEL
2 Stück Artikelnummer 435760 - für Anlage MATRIX 4200 E -
400 V - 50/60 Hz - Seriennummer ...................................
ES
Pedido de las piezas de repuesto
Para pedir piezas de repuesto indiquen claramente:
1) El número de código del particular
2) El tipo de instalación
3) La tensión y la frequencia que se obtien de la chapa datos colocada sobre la instalación
4) El número de matrícula de la soldadora misma
EJEMPLO
N. 2 piezas código 435760 - para instalación MATRIX 4200
E - 400 V - 50/60 Hz - Matrícula N. .......................................
NL
Bestelling van reserveonderdelen
Voor het bestellen van onderdelen duidelijk aangeven:
1) Het codenummer van het onderdeel
2) Soort apparaat
3) Spanning en frequentie op het gegevensplaatje te vinden
4) Het serienummer van het lasapparaat
VOORBEELD
N. 2 stuks code 435760 - voor apparaat MATRIX 4200 E - 400
V - 50/60 Hz - Serie Nummer ...................................
EXEMPLO
N° 2 peças código n. 435760 - para o equipamento MATRIX 4200 E - 400 V - 50/60 Hz
Matrícula n. ...............................
SV
Beställning af reservdelar
Vid förfrågan av reservdelar ange tydligt:
1) Detaljens kodnummer
2) Typ av apparat
3) Spänning och frekvens - den står bland tekniska data påapparatens märkplåt
4) Svetsens serienummer
EXEMPEL
2 st. detaljer kod 435760 - för apparat MATRIX 4200 E - 400 V
- 50/60 Hz - Serienummer ......................................
FI
Varaosien tilaus
Tiedustellessanne varaosia, ilmoittakaa selvästi:
1) Osan koodinumero
2) Laitteiston tyyppi
3) jännite ja taaiuus, jokta on ilmoitettu laitteistolle sijoitetusta tietokyltistä
4) Hitsauskoneen sarjanumero
ESIMERKKI
2 osaa, koodi 435760 - laitteistoon MATRIX 4200 E - 400 V -
50/60 Hz - Sarjanumero ................................................
N
Bestilling av reservedeler
Ved bestilling av reservedeler må du oppgi:
1) Delenes kodenummer
2) Type apparat
3) Apparatets spenning og frekvens som finnes på merkeplaten for data på apparatet
4) Sveiseapparatets serienummer
EKSEMPEL
2 stk. kode 435760 - for apparat MATRIX 4200 E - 400 V -
50/60 Hz - Serienummer................................................
EL
 Πααγγελίατωναανταλλακτικών
Οταν ξητάτε ανταλλκτκά παρακαλείσθε να ημειώνετε καθαρά:
1) τον κωδικό της λεπτομέρειας
2) τον τύπο της μονάδας ψύξης
3) την τάση και τη σχνόητα που αναγράφονται στηνπινακίδα των τεχνικών χαρακτηριοτικών
4) τον αριθμό μητρώου της μηχανής
Αριθ.
2 τεμάχια κωδικό 435760 για τη μαονάδα ψύξης MATRIX 4200
E - 400 V - 50/60 Hz - Αριθ. Μητρώου .............................
RU
 Заказзапасныхчастей
Для запроса запасных частей укажите точно:
1) код запчасти,
2) модель машины,
3) напряжение и частоту, написанные на пластине,
4) ее серийный номер.
ПРИМЕР
2 шт., код № 435760, для сварочной машины MATRIX 4200
E - 400 B - 50/60 Hz
Серийный номер ..............................
6
EN
Operator’s manual
READ CAREFULLY
CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A.
C.so E. Filiberto, 27 - 23900 Lecco - Italy
MX 22 - 27 - 28 - 42
Cas. Post. (P.O.BOX) 205
E-mail: cea@ceaweld.com - web: www.ceaweld.com
EN
ENGLISH
Introduction 10
Control panel 10
Switching on the welding machine and initial screen 12
Displaying the software version installed 12
MMA welding (Electrode) 12
TIG welding 13
Creating and memorising automatic welding points 13
Recalling automatic welding points 14
Activating the VRD device 14
Accessory functions 15
Error and protection conditions 16
Control panel
KEY AND KNOB CONTROLS
Introduction
This manual describes the functions on and how to use the fol­lowing control panels:
MX 22 fitted on the MATRIX 2200 E welding machine.
MX 27 fitted on the MATRIX 2700 E - MATRIX 2700 E SV
welding machines. MX 28 fitted on the MATRIX 2800 E - MATRIX 2800 E-MG
welding machines. MX 42 fitted on the MATRIX 420 E - MATRIX 420 E-MG -
MATRIX 4200 E - MATRIX 4200 E-MG welding machine.
The figures shown in this manual show the MX 42 panel as an example, but the way the three panels listed above work is identical (same functions but different characteristics depend­ing on the type of machine they are fitted on, such as current regulation range). For general information on how the MATRIX 2200 E - 2700 E -
2700 E SV - 2800 E - 2800 E-MG - 420 E - 420 E-MG - 4200 E
- 4200 E-MG welding machines work, see the individual man-
uals provided with the machines.
DISPLAY SELECTION key
WELDING PROCESS SELECTION key
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■ DISPLAY SELECTION key
When this key is pressed the DISPLAY can show the CUR­RENT (A) or VOLTAGE (V) values corresponding to the DIS­PLAY INDICATION LED switched on.
■ WELDING PROCESS SELECTION key
This can be used to select the following 4 welding processes, and each time the key is pushed the welding machine selects the next welding process, in the following order:
1) ELECTRODE. 3) Stainless steel ELECTRODE.
ENCODER knob
FUNCTION
SELECTION key
■ ENCODER knob
On the basis of the corresponding LED switched on, this can be used to regulate the following values:
1) Regulation of the current values (A).
2) DOES NOT ALLOW the voltage (V) val­ues to be regulated, but when the knob is rotated you go back to regulating the current value (A).
3) Regulation of the values for the HOT START function.
2) Cellulose ELECTRODE.
4) TIG with “Lift” type ignition.
4) Regulation of the values for the ARC FORCE function.
2
■ FUNCTION SELECTION key
When one of the three electrode welding processes available on the welding machine is activated, this key is used to se­lect the HOT START and ARC FORCE functions, the values for which can be regulated by means of the ENCODER knob. Each time the key is pressed the welding machine switches to selecting the next function in the following order:
• HOT START.
• ARC FORCE.
DISPLAY AND LED INDICATIONS
DISPLAY INDICATION LED
• Exit the functions - DISPLAY INDICATION LED
welding machine ready again to weld at the current indicat­ed on the DISPLAY.
If it is held down for about 5 seconds, the FACTORY DEFAULT setting for the welding machine is activated, that is, the ma­chine’s parameters are returned to their settings when they left the factory.
on and
VRD
LED
WELDING PROCESS SELECTION LED
DISPLAY
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■ DISPLAY INDICATION LED
1) When this LED is on it means that the DISPLAY is showing the CURRENT val­ue (the value displayed depends on and can be regulated on the basis of the type of process or function selected).
2) When this LED is on it means that the DISPLAY is showing the VOLTAGE value (the value displayed cannot be changed or regulated, but merely indicates the ac­tual VOLTS on the quick connections for the welding machine’s positive and neg­ative poles).
■ WELDING PROCESS SELECTION LED
When one of these LEDs is on it means that the correspond­ing welding process has been selected.
■ VRD LED
The Voltage Reduction Device (VRD) is a safety device that reduces the voltage. It prevents voltages forming on the output terminals that may pose a danger to people. Two-tone LED (off - red - green) indicates enabling of the VRD device. The standard, preset settings for the CEA do not activate the VRD function on the welding machine and so this LED is nor­mally off (to activate the VRD device see the relevant para­graph).
HOT START and ARC
FORCE SELECTION LED
■ HOT START and ARC FORCE SELECTION LED
These two LEDs can only be on when welding in MMA.
1) When this LED is on it means that the operator can use the ENCODER Knob to regulate the value shown on the DIS­PLAY for the HOT START function.
2) When this LED is on it means that the operator can use the ENCODER Knob to regulate the value shown on the DIS­PLAY for the ARC FORCE function.
■ DISPLAY
Displays, in numerical format, the selections made using the DISPLAY SELECTION key or the FUNCTION SELECTION key and regulated using the ENCODER knob.
• When the When the machine is in stand-by, the
­Amps (A) set. When the machine is welding the real
­Amps (A) at which the operator is actu­ally welding.
When the LED is on it displays the real VOLTS (V) at the quick connections for the machine’s positive and negative poles.
When the HOT START LED is on the nu­merical value the operator has set for the HOT START function is displayed.
When the ARC FORCE LED is on the nu­merical value the operator has set for the ARC FORCE function is displayed.
LED is on it displays:
3
Switching on the welding
machine and initial screen
1) Start the welding machine by pushing the switch on the rear panel to position I.
2) The welding machine carries out a short MACHINE CHECK (all the LEDs switch on and off, one at a time, following a preset, established start-up procedure. Then the display shows the following message “---”).
3) Next the control panel display’s the INITIAL SCREEN for the machine, which is then ready to weld, and the DISPLAY shows the last numerical value set (example: 80) for the CURRENT. Remember that since the welding machine is in stand-by mode this value (in Amps) is not real but is the setting.
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Displaying the software
version installed
1) When the welding machine is running, hold the WELDING PROCESS SELECTION key (T1) and FUNCTION SELEC­TION key (T2) down simultaneously, for at least 3 seconds.
C00-02.06 indicates the version of WELDING CURVES installed.
MMA welding (Electrode)
1) Start the welding machine by pushing the switch on the rear panel to position I.
2) Push the WELDING PROCESS SELEC­TION key to select one of the 3 electrode welding processes according to the elec trode material you are using:
ELECTRODE
For welding with coated electrodes: Rutile, basic, cast iron, and aluminium.
Cellulose ELECTRODE
For welding with cellulose electrodes.
NOTE: Only valid for the MATRIX 2700 E - 2700 E SV welding machines. In order to optimise fusion and the stability of the cel­lulose electrode weld, the welding machine automatically acti­vates a booster in this position only, which provides the welding machine with further power. This booster works at a MAX cur­rent of up to 130 A. We therefore recommend using cellulose electrodes for welding with currents up to 130 A. Once this val­ue is exceeded the booster is deactivated automatically, and so instability and interruptions in the arc may occur.
Stainless steel ELECTRODE
For welding stainless steel. Thanks to the special dynamic characteristic it is possible to weld with a soft, extremely stable arc in order to achieve high quality welds.
-
T1 T2
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2) The DISPLAY continuously runs the message shown in Fig­ure A, indicating the SOFTWARE VERSION INSTALLED on the welding machine, until the two-key combination is pushed again. In detail, the meaning is as follows:
H04-04.02 indicates the version of HARDWARE in-
stalled. F04-01.00 indicates the version of FIRMWARE installed.
3) Turn the ENCODER Knob (E) until the DISPLAY shows the CURRENT VALUE at which you wish to weld, in rela­tion to the diameter of the electrode you are using.
D
E
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FIG. A
4
4) To improve the quality of the welding the following acces­sory functions are available that relate to the MMA weld­ing process selected:
HOT START - This increases the welding current, in per-
centage terms, for a time interval that can be set at the start of the welding process, thereby reducing the risk of poor fusion at the start of the joint (HOT START - 0-100
- regulation step: 1). ARC FORCE MMA - Regulates, in percentage terms, the
dynamic characteristics of the arc (ARC FORCE - 0-100
- regulation step: 1).
WARNING: Both the values for the accessory functions are pre-set at a value of 50, which is the value deemed best for welding.
To select these two accessory functions, simply press the FUNCTION SELECTION key (T2) and regulate the value us­ing the ENCODER Knob (E).
E
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T2
3) Turn the ENCODER Knob (E) until the DISPLAY shows the CURRENT VALUE at which you wish to weld.
D
E
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4) Once the all the selections/regulations indicated above have been made, welding can begin.
Creating and memorising
automatic welding points
Once you have defined the parameters that characterise a new automatic welding point (abbreviated as JOB), it can be stored in the memory in the following manner:
1) Hold down the WELDING PROCESS SELECTION Key for at least 5 seconds, until the DISPLAY (D) shows a flashing message that represents the first AUTOMATIC WELDING POINT (JOB) free and/or available, in which the data can be saved (example: F08).
5) Once the all the selections/regulations indicated above have been made, welding can begin.
TIG welding
1) Start the welding machine by pushing the switch on the rear panel to position I.
2) Press the WELDING PROCESS SELEC­TION Key and select the following pro­cess:
TIG with “Lift” type ignition
With TIG welding using the innovative “Lift” type thermally controlled ignition TCS), ig­nition come about precisely and quick­ly, reducing the inclusions of tungsten to a minimum and doing away with incisions into the workpiece to be welded. The SWS (Smart Welding Stop) system avoids oxida­tion of the welded joint.
D
T1
2000HA90
In order to choose another free JOB simply rotate the EN-
CODER knob and see the other JOBS available. The MX control panel allows you to save a maximum of 99 AUTO­MATIC WELDING POINTS (JOBS).
5
2) To SAVE the JOB simply push the WELDING PROCESS SELECTION Key (T1) again until the DISPLAY reads “StO” for about 1 second, which confirms that the JOB has been saved and then the automatic point chosen (for example: A08).
T1
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Once the saving operation has been completed the control
panel automatically goes to the last JOB saved.
If the user wants to weld in this way they do not need to
adjust any parameter, but if they wish they can view them by pressing the relevant keys.
NOTE: Creating a JOB implies saving all the special functions associated with it.
3) To exit the JOB, hold the DISPLAY SELECTION key down for at least 5 seconds. The welding machine will au
­tomatically load the values for the JOB from which it comes.
Recalling automatic welding points
To recall a JOB saved previously:
1) Enter JOB mode by holding the DISPLAY SELECTION key (T3) down for at least 5 seconds.
2) Rotate the ENCODER knob (E) until you find the JOB re­quired.
T3
E
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Activating the VRD device
To activate the VRD device, which must be done when the welding machine is switched off:
1) Use a suitable screwdriver to unscrew the 4 screws that fix the MX control panel to the welding machine.
2) Remove the “VRD” JUMPER on the DIGITAL INTERFACE BOARD (Fig. B).
3) Use a suitable screwdriver to tighten the 4 screws that fix the MX control panel to the welding machine.
4) Start the welding machine by pushing the switch on the rear panel to position I.
When the MX control panel switches on the VRD LED will come on and will be GREEN, which means that the VRD func­tion is on.
To “deactivate” the VRD device and therefore start to weld, fol­low this simple procedure: First touch the workpiece with the electrode, then detach it and ignite the arc within a MAX of 0,3 seconds, otherwise if this time is exceeded the VRD device starts and prevents welding.
FIG. B
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6
During welding the VRD LED turns RED, which does not indi­cate any malfunction on the welding machine, but that the VRD device has been deactivated to allow welding.
Accessory functions
4) Hold the SELECT FUNCTION (T2) key down to confirm the choice made previously.
“Energy saving”
This function manages correct functioning of the cooling fan that only runs when strictly necessary, to guarantee lower en­ergy consumption, that is:
During welding or for an adequate period of time after this
• is finished. When the thermostat intervenes or for an adequate period
• of time after it has just been reset.
Hold
During welding the operator can decide whether to display the VOLTAGE and CURRENT values on the DISPLAY by simply pressing the DISPLAY SELECTION Key. When welding ends for about 15 seconds the DISPLAY mem­orises the last parameter values (VOLTAGE and CURRENT) selected / regulated (HOLD FUNCTION). These values can be seen by simply pressing the DISPLAY SELECTION Key. To interrupt the display before the 15 seconds are up, simply rotate the ENCODER Knob.
Aut - rEm - LoC
Matrix generators can be fitted with a manual remote control that allows the welding current to be remote controlled (value adjustable according to the model of the MX control panel you are using). When this is on, the welding machine’s DISPLAY will show the current value set previously using the same re­mote control. The MX control panel allows the operator to choose between 3 different parameter adjustment modes, by means of this sim­ple procedure:
1) Switch off the welding machine by turning the main switch
to position 0.
2) Hold down the SELECT FUNCTION (T2) key and simulta-
neously switch in the welding machine by turning the main switch to position I.
3) Now, when the ENCODER knob (E) is rotated the DISPLAY
(D) will provide the following indications and the operator can choose between:
Aut - Automatic recognition of the manual remote control
• connected up (DEFAULT setting) and therefore allowing the current to be adjusted.
rEm - Automatic recognition of the manual remote con­trol connected up and therefore allowing the current to be adjusted.
PLEASE NOTE: The welding machine does not work if the remote control is not connected to it!
LoC - The welding current may only be adjusted from the
• welding machine’s control panel.
WARNING: The remote control does not work, even if connected up correctly!
D
E
T2
NOTE: The MX control panel has a STAND-BY function that, when the remote control is on, switches off the inverter when the minimum welding current value is reached (to reinstate nor­mal, correct functioning of the machine, increase the welding current value by rotating the remote control knob).
Factory default
WARNING: This operation results in complete resetting of all
parameters to the factory settings (FAC).
To reset the settings hold the FUNCTION SELECTION Key (T2) down for at least 5 seconds, until the DISPLAY reads FAC.
T2
2000HA90
At this point the welding machine carries out a short MACHINE CHECK (all the LEDs switch on and off, one at a time, follow­ing a preset, established start-up procedure). The reset proce­dure has now been completed successfully.
7
Error and protection conditions
D
The equipment is protected against problems and if any arise the DISPLAY shows fixed or flashing (error code) messages (depending on the type of error) that serve to inform the oper­ator that a fault has occurred in the equipment (see table 1). The table provides a summary of all the error conditions that may arise on the equipment and, if possible, what the opera­tor must do to attempt to resolve the problem. The table contains 2 types of errors:
Errors reset automatically: once the alarm condition has
• been resolved the equipment starts working again and the operator can weld again! Errors NOT reset automatically: To eliminate the alarm
• states and reinstate correct functioning of the machine, the equipment must be switched off. When it is switched on again, the machine will be working again and the operator can weld again!
PLEASE NOTE: If when it switches on the error condition recurs, contact the technical assistance immediately.
All of this is necessary to allow our technical assistance de­partment (which must be contacted each time error mes- sages appear on the equipment’s operator interface) to resolve problems more easily, as quickly as possible and thanks to the user’s reports, also because, in the meantime the machine will not allow the operator to do their work.
Table 1
Display Diagnosis
UNDER & OVER VOLTAGE
E0.1
E0.2
E0.3
Automatic reset error. If the fault persists look for the cause of the fault and contact our technical assistance department if necessary.
OVER VOLTAGE
This is activated when the power supply voltage to the equipment exceeds 480 V. Automatic reset error. The welding machine stops automatically and resets itself automatically when the voltage returns within the limits again. If the fault persists look for the cause of the fault and contact our technical assistance department if necessary.
UNDER VOLTAGE
This is activated when the power supply voltage to the equipment is less than:
320 V (MATRIX 2700 E - MATRIX 2800 E - MATRIX 2800 E-MG - MATRIX 420 E - MATRIX 420 E-MG - MATRIX 4200 E - MATRIX 4200 E-MG)
180 V (MATRIX 2700 E SV)
Automatic reset error. The welding machine stops automatically and resets itself automatically when the voltage returns within the limits again. If the fault persists look for the cause of the fault and contact our technical assistance department if necessary.
Display Diagnosis
PRIMARY OVER CURRENT
This is activated when the primary current goes beyond dangerous values.
E0.4
E0.5
E1.0
E1.1
E2.0
E4.0
t°C
Automatic reset error. The welding machine stops automatically and resets itself automatically when the current returns within the limits again. If the fault persists look for the cause of the fault and contact our technical assistance department if necessary.
POWER FAIL NON automatic reset error. Immediately contact technical assistance dept.
CONFIGURATION FILE MISSING NON automatic reset error. Immediately contact technical assistance dept.
USER FILE MISSING NON automatic reset error. Immediately contact technical assistance dept.
FILE SYSTEM ERROR NON automatic reset error. Immediately contact technical assistance dept.
USER SETTINGS MISSING NON automatic reset error. Immediately contact technical assistance dept.
THERMAL PROTECTION
The welding stops due to an excessively high temperature (thermostat activated). Automatic reset error.
WARNING: Errors E0.1 – E0.2 - E0.3 cannot be picked up on the MX22 control panel!
WARNING: The MATRIX 2200E welding machine has a built-in electronic protective device to deal with fluctua­tions in mains voltage that switches the machine off auto­matically (voltage exceeding 300 V), without indicating any type of error or warning message for the operator. Subse­quently it starts functioning again automatically when the voltage has dropped to below the value indicated above.
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CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A.
C.so E. Filiberto, 27 - 23900 LECCO - ITALY Cas. Post. (P.O. BOX) 205 Tel. +39 0341 22322 - Fax +39 0341 422646 cea@ceaweld.com www.ceaweld.com
ISO 9001: 2008
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