Migatronic PILOT 1800, PILOT 2400 Instruction Manual
PILOT 1800/2400
Betjeningsvejledning
Instruction manual
Betriebsanleitung
Manuel d'instruction
Bruksanvisning
Manuale d'ist r uzione
Gebruikershandleiding
50113116 A
EC DECLARATION OF CONFORMITY
MIGATRONIC A/S
Aggersundvej 33
9690 Fjerritslev
Denmark
hereby declare that our machines as stated below
Type: PILOT 1800/2400
as of: week 40, 2001
conforms to directives 73/23/EEC and 89/336/EEC.
European Standards: EN60974-1
EN50199
Issued in Fjerritslev on 1st October 2001.
Peter Roed
Managing director
0227
13
ENGLISH
Electromagnetic emissions and the radiation of electromagnetic disturbances
This welding equipment for industrial and professional use is in
conformity with the European Standard EN50199. The purpose of
this standard is to prevent the occurrence of situations where the
equipment is disturbed or is itself the source of disturbance in
other electrical equipment or appliances. The arc radiates
disturbances, and therefore, a trouble-free performance without
disturbances or disruption, requires that certain measures are
taken when installing and using the welding equipment. The user
must ensure that the operation of the machine does not occasion
disturbances of the above mentioned nature.
The following shall be taken into account in the surrounding area:
1. Supply and signalling cables in the welding area which are
connected to other electrical equipment.
2. Radio or television transmitters and receivers.
3. Computers and any electrical control equipment.
4. Critical safety equipment e.g. electrically or electronically controlled guards or protective systems.
5. Users of pacemakers and hearing aids etc.
6. Equipment used for calibration and measurement.
7. The time of day that welding and other activities are to be
carried out.
8. The structure and use of buildings.
If the welding equipment is used in a domestic establishment it
may be necessary to take special and additional precautions in
order to prevent problems of emission (e.g. information of temporary welding work).
Methods of reducing electromagnetic emissions:
1. Avoid using equipment which is able to be disturbed.
2. Use short welding cables.
3. Place the positive and the negative cables close together.
4. Place the welding cables at or close to floor level.
5. Remove signalling cables in the welding area from the supply
cables.
6. Protect signalling cables in the welding area, e.g. with
selective screening.
7. Use separately-insulated mains supply cables for sensitive
electronic equipment.
8. Screening of the entire welding installation may be considered under special circumstances and for special applications.
WARNING
Arc welding and cutting can be dangerous to the user, people working nearby, and the surroundings if the
equipment is handled or used incorrectly. Therefore, the equipment must only be used under the strict
observance of all relevant safety instructions. In particular, your attention is drawn to the following:
Electricity
- The welding equipment must be installed according to safety regulations and by a properly trained and qualified
person.
- Avoid all contact with live components in the welding circuit and with electrodes and wires if you have bare hands.
Always use dry welding gloves without holes.
- Make sure that you are properly and safely earthed (e.g use shoes with rubber sole).
- Use a safe and stable working position (e.g. avoid any risk of accidents by falling).
- Make sure that the welding equipment is correctly maintained. In the case of damaged cables or insulation work
must be stopped immediately in order to carry out repairs.
- Repairs and maintenance of the equipment must be carried out by a properly trained and qualified person.
Light and heat emissions
- Protect the eyes as even a short-term exposure can cause lasting damage to the eyes. Use a welding helmet with
suitable radiation protection glass.
- Protect the body against the light from the arc as the skin can be damaged by welding radiation. Use protective
clothes, covering all parts of the body.
- The place of work should be screened, if possible, and other persons in the area warned against the light from the
arc.
Welding smoke and gases
- The breathing in of the smoke and gases emitted during welding is damaging to health. Make sure that any exhaust
systems are working properly and that there is sufficient ventilation.
Fire hazard
- Radiation and sparks from the arc represent a fire hazard. As a consequence, combustible materials must be
removed from the place of welding.
- Working clothing should also be secure against sparks from the arc (e.g. use a fire-resistant material and watch out
for folds and open pockets).
Noise
- The arc generates surface noise according to welding task. In some cases, use of hearing aids is necessary.
Use of the machine for other purposes than it is designed for (e.g. to unfreeze water pipes) is strongly deprecrated. If
occasion should arise this will be carried out without responsibility on our part.
Read this instruction manual carefully
before the equipment is installed and in operation
14
MACHINE PROGRAMME
PILOT 1800/2400 is a line of portable welding
machines, especially designed for welding where
weight and dimensions have to be small.
The machine is available in six versions:
PILOT 1800 E PILOT 2400 E
PILOT 1800 H PILOT 2400 H
PILOT 1800 HP PILOT 2400 HP
All versions are included in this instruction manual.
PILOT 1800 E / 2400 E
MMA welding machines with a max. current of respectively 180 A and 240 A. The machine has adjustable Arc-power and hot start and can be
equipped with connection for external adjustment.
PILOT 1800 H / PILOT 2400 H
MMA and TIG welding machines with a max. current
of respectively 180 A and 240 A. The machine has
adjustable Arc-power and hot start for MMA welding
and adjustable pre-flow, post-flow and slope-down
for TIG welding. Moreover, it possible to choose between 2-times and four times welding and between
HF and LIFTIG ignition. The machine can be
equipped with connection for external adjustment
and connection for cooling module for torch cooling.
PILOT 1800 HP / PILOT 2400 HP:
MMA and TIG welding machines with a max. current
of respectively 180 A and 240 A. Moreover, the
machine can be used for pulse welding. In
connection with pulse welding it is possible to adjust
pulse time, pause time and base amp. The machine
has a pilot arc. The machine has adjustable Arcpower and hot start for MMA welding and
adjustable pre-flow, post-flow, starting current,
slope-up, reduced current, slope-down, and stop
current for TIG welding. Moreover, it possible to
choose between two-times, four-times and spot
welding and between HF and LIFTIG ignition. The
machine can be equipped with connection for
external adjustment and connection for cooling
module for torch cooling. The machine memorises 8
and 16 complete welding settings respectively.
Transportation equipment
The MIGATRONIC programme includes a transport
trolley and shoulder strap which can be used for alle
PILOT versions.
Hoses
The machine can be equipped with TIG welding
hoses, electrode holders and return current cables
from the MIGATRONIC programme. If a TIG torch
with adjustment is used, the welding current can be
adjusted from the torch.
External adjustment
Remote control and foot control units can be delivered to PILOT machines with connection for
external adjustment.
Torch cooling module
A torch cooling module can be delivered to PILOT
machines with TIG which enables use of TIG
welding torches from the MIGATRONIC
programme.
15
INITIAL OPERATION
Mains connection
PILOT 1800/2400 must be connected to a mains
supply with 3 phases and protection earthing. After
the mains plug has been connected to the mains
cable (5) the machine is ready for use. Please note
that all cable connections must be made by
authorised and qualified staff. Switch on and off the
machine by means of the breaker (7) on the rear of
the machine.
Configuration
MIGATRONIC disclaims all responsibility for
damaged cables and other damages related to
welding with under sized welding torch and welding
cables measured by welding specifications e.g. in
relation to permissible load.
Gas connection
Connect the machine to the gas system by means
of a gas flow control. Press the gas hose mounted
with a quick connection on the gasconnection on the
rear of the machine (8).
Connection of welding cables
Connect the welding cables and the return current
cable to the front of the machine (1 and 2). Please
note that the plug must be turned 45 degrees after
insertion into the socket - otherwise the plug can be
damaged due to excessive contact resistance.
Connect always the TI G connection in the minus (-)
tap (2) and the return current cable in the plus (+)
tap (1).
The control signals from the TIG torch are transformed to the machine through the circulary 7-poled
plug (4). When the plug has been assembled please
secure it by turning the "circulator" clockwise.
Connect the gas hose to the quick connection (3).
Electrodes are marked with a polarity on the packing. Mount the electrode tongs in accordance with
this marking to the plus/minus taps of the machine
(1 and 2).
Connection of external adjustment
Connect the remote control unit on the rear of the
machine on the circulary 8-poled plug (9).
Connection of a cooling module
Fastened the module under the machine with the
fitting (15). Mount the 4-poled plug (16) in the
corresponding socket in the machine (10). Mount
the flow hose on the water cooled torch in the quick
connection marked with blue (11) and the return
hose in the quick connection marked with red (12).
Control of cooling liquid and draining
The cooling liquid level can be inspected in the
inspection cover frame (13). Refillment of cooling
liquid should be carried out behind the cover (14). In
case of problems when starting up, the drain plug
(17) should be loosened.
Usage of the machine
(PILOT 2400)
When welding with PILOT 2400 machines a heating
of various components of the machine takes place
and during breaks these components will cool down
again.
It must be ensured that the air intake and outlet are
not blocked.
It is not possible to overload the machine in normal
use, and there is no need for cooling down periods
at current settings up to 160 Amps. When the
machine is set for welding currents higher than
these, there will be a need for periods during which
the machine can cool down.
The length of these periods depends on the current
setting, and the machine should not be switched off
in the meantime. If the periods for cooling down
during use of the machine are not sufficiently long,
the overheating protection will automatically stop the
welding process and the yellow LED will come on.
The yellow LED switches off when the machine has
cooled down sufficiently, and the machine is ready
for welding. Max. load is:
100% max. load 160 A
60% max. load 200 A
35% max. load 240 A
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