ESAB LAY 500 Instruction manual

LAY 500

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Bruksanvisning
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Manuel d’instructions

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Instrucciones de uso
Istruzioni per l’uso
Manual de instruções

ПдзгЯет чсЮуещт

Instrukcja obs³ugi

Valid for serial no. --xxx--xxxx0349 301 032 GB

1. DECLARATION OF CONFORMITY ........................................................................................................ 48

2. SAFETY.................................................................................................................................................... 48

3. INTRODUCTION ...................................................................................................................................... 50

3.1 GENERAL INFORMATION .................................................................................................................... 50

3.2 TECHNICAL DATA................................................................................................................................. 50

3.3 LAY 500 PACKAGE CONTENT............................................................................................................. 50

4. INSTALLATION........................................................................................................................................ 51

4.1 GENERAL INFORMATION .................................................................................................................... 51

4.2 WORK ENVIRONMENT......................................................................................................................... 51

4.3 INSPECTION.......................................................................................................................................... 51

4.4 POWER SUPPLY CONNECTION ......................................................................................................... 51

4.5 START-UP AND OPERATION OF UNIT ............................................................................................... 51

5. SERVICING .............................................................................................................................................. 55

5.1 ADJUSTING AND SIGNALING ELEMENTS ......................................................................................... 55

6. SELECTION OF WELDING PARAMETERS........................................................................................... 57

7. MAINTENANCE ....................................................................................................................................... 57

7.1 CLEANING ............................................................................................................................................. 57

8. SPARE PARTS LIST ............................................................................................................................. 146

9. ORDERING OF SPARE PARTS............................................................................................................ 150

10. SCHEMATIC DIAGRAM..................................................................................................................... 150

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1. DECLARATION OF CONFORMITY

-

DECLARATION OF CONFORMITY

Esab Welding Equipment AB, S-695 81 Laxå, Sweden, gives its unreserved guarantee that
welding power source LAY 500 from serial number 929 complies with standard EN 60974-1, in
accordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with
standard EN 50199, in accordance with the requirements of directive (89/336/EEC) and addendum
(93/68/EEC).

----------------------------------------------------------------------------------------------------------------------------------

Göteborg 99-09-29

Bo Sjöberg
Managing Director
ESAB AB
Box 8004
402 77 Göteborg
Sweden Tel: [phone] Fax: [phone]

2. SAFETY

User of welding equipment bears full responsibility for safety of operators and personnel working nearby.

Improper operation can cause abnormal situation, injuries to operator and damage of equipment.

All persons using welding equipment must be fully familiar with the following:

- -servicing of equipment,

- localisation of emergency switches,

- functions of equipment,

- applicable safety regulations,

- metal protective gas welding processes.

Operator must be sure of the following:

- no person is in working zone during start-up of welding unit

- all persons outside working zone are protected with appropriate screen or shield.

Working zone must be:

- free from machine parts, tools and other objects which can be in the way of operator during work

- organised so that three is easy access to emergency switches

- free from draught.

Personal protective equipment must be:

- always properly used, i.e. shield or head screen fireproof protective clothing, gloves and boots

- do not wear loose clothes, belts, bracelets, rings etc. to avoid accidents and burns.

Other:

- arc welding equipment can be operated by authorised personnel only

- check mass wire connection,

- provide easy access to fire equipment in special clearly marked places at arc welding workplace,

- unit maintenance must not be performed when unit is in operation.

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! WARNING !
WELDING PROCESSES CAN BE DANGEROUS FOR OPERATOR AND OTHER PERSONS KEEP
EXTREME CAUTION DURING WELDING. FOLLOW SAFETY INSTRUCTIONS OBLIGATORY IN A
COMPANY, PREPERED ACCORDING TO EQUIPMENT MANUFACTURER’S RECOMMENDATIONS.

ELECTRIC SHOCK – can cause death

• Install the unit according to obligatory regulations.

• Do not touch with bare hands or wet gloves any live elements, including electrodes.

• Ensure safety of workplace.

SMOKE AND GASES – can be harmful.

• Keep head away from stream of smoke.

• Provide ventilation plus smoke and gas exhaust from working area.

ARC RADIATION – can cause grave damages to sight and skin.

• Protect eyes and body. Use appropriate head screen or shield with proper filter glass and protective

clothing.

• Protect other personnel with appropriate screens and shields

FIRE DANGER

• Metal spattering can cause fire. Check for flammable materials in the vicinity of work place.

INAPPROPRIATE OPERATION OF EQUIPMENT - if a unit works in the faulty way, consult a trained
technician.

READ AND COMPRAHEND THE UNIT OPERATION MANUAL BEFORE INSTALLATION OR START-UP OF UNIT

PROTECT YOURSELF AND OTHERS!

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3. INTRODUCTION

! WARNING !
All guarantee obligations of producer become nullified if customer attempt to repair any faults by
himself

Warning: Producer reserves the right to modify the product without notice.

3.1 GENERAL INFORMATION

LAY 500 is a welding source designed to supply power for metal protective gas welding process. The unit is
designed to co-operate with feeding unit MEK 4 and MEH 44.

3.2 TECHNICAL DATA

Mains voltage 3x400V, 50Hz
Power cable cross-section 4x6mm

2

Mains fuse 35 A delayed
Rated power consumption 27 kVA
Rated primary current @ P60% 39A
Rated welding current Duty cycle* 60% 500A

Duty cycle* 100% 390A
Welding current range
Open circuit voltage
Dimensions Length

Width
Height

50÷500A
18÷55V
1080

515

920
Mass ~238kg
Flow of cooling liquid @ 2,5 bar 1 dm3/min (60l/h)
Selection of cooling liquid depending on ambient temperature

- Distilled water

- Solution of 30% Antifreeze Coolant +70% distilled water to -10°C

Tank capacity 5 dm

from 0°C to +40°C

to -10°C

3

*Duty cycle is based on 10-minute period. Duty cycle 60% means that after 6 minute of unit operation, 4
minutes break is required. Duty cycle 100% means that the unit can work continuously.

WARNING - The unit is characterised by the following:

- Safety class IP 23; adjusted to work indoors

- Application class S, adjusted to work in areas with increased risk of electric shock.

3.3 LAY 500 PACKAGE CONTENT

No. Part no Description

1 1 0349 302 001 Welding source LAY 500
2 1 0349 301 032 LAY 500 technical documentation
3 1 0349 302 039 Current cable
4
5 1 0349 302 030 Fuse link 2A
6 1 0349 302 031 Fuse link 4A
7 1 0349 302 035 Fuse link 8A
8 1 0349 302 040 Water link
9 1 0156 654 883 Guide pin

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4. INSTALLATION

4.1 GENERAL INFORMATION

Proper installation of LAY 500 is necessary in order to secure correct operation. Read the enclosed
documentation carefully and follow the suggested recommendations.

4.2 WORK ENVIRONMENT

In order to provide adequate cooling of welding source, good ventilation is necessary for cooling LAY 500
unit. The unit must be protected from dust, dirt and overheating. Therefore a distance of min. 300 mm must
be kept between LAY 500, walls and other obstacles blocking air-flow though the unit.

! WARNING !
Installation or connection of any filter unit limits cooling air-flow, therefore some welding source
elements may overheat. Use of any filters nullifies guarantee.

4.3 INSPECTION

A. Unpack unit and check for hidden faults which could be unnoticed at LAY 500 take over. Notify supplier

(distributor) if any faults or damages are found.
B. Check if no parts are left in packaging before disposal.
C. Check that all ventilation openings are opened.

4.4 POWER SUPPLY CONNECTION

! WARNING !
ELECTRIC SHOCK CAN CAUSE DEATH! All safety precautions must be undertaken to guarantee
maximum protection from electric shock. Before implementing any internal connections, set main
switch (in switch box) to off position and disconnect power supply cable from mains.

! WARNING !
Make sure that welding source is adjusted to proper mains voltage. Welding source adjusted to
3x400V voltage MUST NOT be supplied with 440V otherwise it can be damaged.

LAY 500 units are equipped with 5 m long four wire cables with allow for connecting three-phase voltage
3x400V. Power supply circuit should be protected by main switch and proper fuses or automatic switches,
appropriated to nominal power supply parameters (see TECHNICAL DATA)

! WARNING !
Casing must be properly earthed. Otherwise it can cause electric shock, burns or even death.

4.5 START-UP AND OPERATION OF UNIT

! WARNING !
Before connecting cables to terminals or output sockets of the unit, disconnect mains switch (in
switch board) and disconnect power supply cable from mains.

1. Put cylinder with shielding gas shelf in the back of power source and protect from falling with a

fastened chain.

2. Remove gas cylinder cap and open valve for a short time in order to remove impurities which might

collect in connector.

3. Install regulator on cylinder.

If CO

used first install gas heater and next regulator on cylinder. Power supply cable to gas heater

2

to be connected to Lay 500 unit through a hole in back panel and connect to terminal strip X2 placed
inside the unit near the hole.

Warning: If neutral or mixed gases are used, gas heater use is not allowed

4. Connect regulator with connector in the back panel of wire feeder by means of gas hose.

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5. Connect current cable with vice to welded elements in spot providing good electrical contact and on

the other side to one of three current sockets "-"

∩, ∩∩ and ∩∩∩ .

6. Connect current socket "+" of welding source and current plug “+” of feeding unit with current cable.

7. Connect welding current source socket and plug of feeding unit with control cable.

8. Connect welding clamp of appropriate nominal current and feeding unit to a quick-connecting joint.

9. Prepare feeding unit to work according to instructions of the manual. Depending on requirements

place feeding unit either on welding source by setting it on guide pin (drawing No. 4.1) or next to
welding source).

10. Fill cooling system tank with cooling liquid> Connect level of cooling liquid is marked with a symbol

on the back panel of welding source.
Depending on ambient temperature, cooling liquid shall be:

- distilled water at temperature 0°C to +40°C

- solution 30% Antifreeze Coolant + 70% distilled water at temperature from -10°C

11. Connect connecting pipes of welding torch cooling installation and proper quick-connecting joints of

wire feeder, next connect wire feeder with welding source, observing that colours of hoses and their
endings are synchronised with colours of quick –connecting joints.

Warning: If welding torches cooled with gas are used (no water cooling), close water cooling system

with a connector supplied with welding source. Connector should be fixed between
connecting pipes of the torch, placed in the front panel feeding unit..

Warning: Welding with water cooled torch with simultaneous closing of cooling system with

connector will damage torch!

Warning: When the unit is tilted by more than 10

over. In order to increase stability of the unit when holder with support arm of wire feeder
is applied, the KIT 0349 302 208 should be assembled. The kit shall be ordered separately,
and it shall be assembled according to the attached instruction.

0

during operation, there is a risk that it might fall

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Fig. 4-1. Diagram of LAY 500 external connections with feeding unit MEK 4 .

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Fig . 4-2. Diagram of LAY 500 external connections with feeding unit MEH 44 .

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5. SERVICING

! WARNING !

Electric shock can cause death

- Do not operate unit without cover,

- Do not move when power on,

- Do not touch nozzle and at current terminal of torch and electrode wire when power supply on

! WARNING !

ARC RADIATION CAN DAMAGE SIGHT AND SKIN AND NOISE CAN IMPAIR HEARING !

- Use head screen with No 8 or 10 filters.

- Use eye, even and body protection.

5.1 ADJUSTING AND SIGNALING ELEMENTS

A. POWER SWITCH (in the front panel of the unit) switches unit on when set at „I” position (fig.5.1, pos.1),

green diode LED is on (fig. 5.1, pos.4) which signals power supply to the units electric circuits. Cooling
fan and pump engine will also be switched on. Green LED diode on (fig.5.1, pos.5) indicates correct
liquid circulation in installation. Pump is disconnected after 5 minutes from the end of welding operation.
After another 5 minute period, fan is disconnected and unit turns into idle mode. Yellow LED diode (fig.

5.1, pos.4) is on at that time. Once the process is started, fan and pump are activated automatically.

Warning: If pump emits irregular noises after activation, it signifies presence of air inside it. In such a
case, unit must be switched off and immediately on again.

B. WELDING LOAD VOLTAGE SETTING is carried out in steps, with a 5-step rotary switch of coarse

adjustment (fig.5.1, pos.2). In each of 5 ranges, the precise voltage value is set with an 8-step rotary
switch (fig.5.1, pos.3).In total, it is possible to select 40 values of welding load voltage.

Warning: Setting of voltage by means of rotary switches (fig. 5.1 pos. 2, 3) during welding (loaded

welding source) can cause damage to unit!

C. OVERHEATING causes automatic switch off of unit, welding operation is stopped: it is impossible to

activate welding process with button on torch. Signal diode LED is on (fig.5.1 pos. 6). Welding process
continuation is possible after temperature drops inside unit.

D. DIGITAL METER (Fig.5.1 pos. 7) indicates actual values of welding current and voltage. Machine LAY

500 is manufactured optionally with or without meter. When machine is not equipped with meter,
customer may install it himself. Meter is delivered to customer with necessary equipment and assembly
instruction 0349 302 047 KIT (meter without HOLD function) or 0349 302 066 KIT (meter with HOLD
function).

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Fig. 5-1. LAY 500 front and back panel view

1. Mains switch

2. Welding voltage coarse control switch (5 step)

3. Welding voltage precise control switch (8 step)

4. Power signal diode (green) or active mode (yellow)

5. Diode signal proper circulation of cooling liquid

6. Diode signal of unit overheating

7. Welding current and voltage meter - KIT 0349 302 066

8. Current socket „ - ”

9. Current socket „ + ”

10. Connection socket for feeding unit control

11. Hole for gas heater power supply cable

12. Power supply cable

13. Pipe connection for liquid (hot liquid)

14. Sight -glass for liquid level control

15. Pipe connection for liquid(cold liquid)

16. Bracket – KIT 0349 302 208 to be ordered separately

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6. SELECTION OF WELDING PARAMETERS

A

φ

Fig. 6.1. Shows approximate welding parameters to be used in steel wire electrode welding. User must set
precise parameters, depending on type of welded materials, type of weld and protective gas.

V

Mixed arc

60

Short-

50

40

30

20

electrodes

circuit arc

0,8

2,0

1,6

1,2

1,2

1,0

Spray arc

50 100 150 200 250 300 350 400 450 500

Thickness of welded elements

1,0

1,5

2,0

3,0

5,0

6,0

8,0

10,0

15,0

Fig 6.1 Approximate welding parameters

7. MAINTENANCE

Warning: All guarantee obligations of producer are nullified if customer attempts to repair any

faults himself.

7.1 CLEANING

LAY 500 unit should be regularly scavenged with dry, pressurised air of lower pressure. If unit is used in dirty
or dusty environment, it should be cleaned more often. Otherwise ventilation openings can be blocked which
can result in overheating

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