Betriebsanleitung
Schweißgeräte mit stufenloser Regelung
Operating Instructions
Welding Transformers and Rectifiers
with Stepless Current Control
Instructions d'utilisation
Appareil de soudure avec réglage en continu
Handleiding
Lasapparaten met traploze instelling
SB 160 C / SB 200 CT
Achtung!
Lesen Sie diese Anleitung vor der Installation und Inbetriebnahme aufmerksam durch.
Attention! Carefully read through these instructions prior to installation and commissioning.
Attention ! Prière de lire attentivement la présente notice avant l'installation et la mise en service.
Oppassen! Lees deze instructies voor de installatie en ingebruikname aandachtig door.
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ENG
Contents
1
Specifications
2
2.1
3
Taking a Single-Phase Machine Into Operation
Taking a Combination 1-Ph/2-Ph Machine into Operation
General Information for Welding Transformer/Rectifier Operators
Overview of Stick Electrodes and their correct Use
3.1
3.1.1 Care of Stick Electrodes
3.1.2 Function of the Stick Electrode Coating
3.1.3 Classification of Stick Electrodes according to DIN 1913
3.1.4 Selecting Suitable Electrodes for a Welding Task
3.1.5 Arc Starting and Arc Burning
3.1.6 Welding Positions According to DIN 1921
4
Welding Hints
4.1
4.2
5
Weld Types
Weld Flaws and possible Causes - Shown on Fillet Welds
Accessories and Accessory Maintenance
Wiring Diagrams
6
You have bought a high-quality electric arc welding machine, designed and built by specialists with many years of
experience. A machine built to last, giving a long service life.
All models have the correct size power supply cable fitted, the transformer‘s core is made from top-quality insulated
sheet steel, to keep eddy currents and cyclic magnetization losses to an absolute minimum.
Please read the instructions given in the manual in order to fully utilize the potential of your machine.
Know and adhere to all local safety codes and regulations governing the operation of electric arc welding machines.
User Responsibility
The operation of the welding divice in the data processing system environment is not allowed!
This product shall only be used as specified. Any other use requires the written consent of Elektra Beckum AG,
P.O.Box 1352, D-49703 Meppen, Germany
Please contact your dealer for any warranty claims.
Warranty work will essentially be carried out by service centres authorised by us. Repairs beyond the warranty
period may be carried out only by our authorised service centres.
Please preserve all repair invoices! We reserve the right to make technical changes!
We recommend attending a welding course at a recognised technical institute.
1
Specifications
Model
Main voltage
Mains frequency
Welding steps
Stepless at 230 V
Stepless at 400 V
Max. OCV at 230 V
Max. OCV at 400 V
Insulation class
SB 160 C
230/400 V
50/60 Hz
stepless
32 - 38 V
38 - 46 V
16 A time-lag
16 A time-lag
H
SB 200 CT
240 V
50 Hz
stepless
47 - 55 V
SB 200 CT
230/400 V
50/60 Hz
stepless
31 - 39 V
41 - 50 V
16 A time-lag
20 A time-lag
H
32 A time-lag
H
Protection class
IP 21
IP 21
IP 21
Setting range, stepless 230 V
Setting range, stepless 400 V
Cooling
30 - 110 A
65 - 155 A
self
70 - 180 A
20 - 110 A
60 - 180 A
fan
fan
Weldable electrodes at 230 V
Weldable electrodes at 400 V
Ø 1.6 - 2.5 mm
Ø 2.0 - 3.25 mm
Ø 2,0 - 4,0 mm
Ø 1.6 - 2.5 mm
Ø 2.0 - 4.0 mm
2
Taking a Single-Phase Machine into Operation
This machine is to be connected to the power mains via a Earth Fault Circuit Interrupter of 30 mA capacity. Worn
or damaged power cables should be replaced immediately by a qualified electrician.
Do not operate this machine with a damaged power cable, danger of personal injury by electric shock.
Children are not permitted to operate this machine.
Connect to an earthed single-phase 230/240 V outlet, protected by a 16 A time-lag fuse. Operating other electric
machines or appliances on the same circuit while welding is only possible to a very limited extent and not
recommended.
Earth and welding cable are firmly attached to the machine.
Polarity does not matter with AC welding current.
13
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Attach earth clamp to the workpiece, close to the weld seam and on bare metal for good conduction.
Place stick electrode into the electrode holder.
With the handwheel select the desired welding current.
If there is not power outlet near the work area an extension cable is required. The cable's lead cross section must be
at least 2.5 mm2. Uncoil extension cable fully to prevent heatbuild-up by inductance. Inductance also conside-rably
reduces the welding current. Extension of the welding cables is also possible, but the cross section of the extension
cables must be larger than that of the cables supplied with the machine.
Every machine is protected against overloads by a thermo switch, which switches the power to the transformer off if it
becomes too hot. After a short cooling-down period the machine will switch back on automatically. Model SB 200 CT
is equipped with a fan for forced cooling, given better performance with a higher duty-cycle.
3
General Information for Welding Transformer/Rectifier Operators
Dust, dirt and metal chips will harm any welding machine. It is of particular importance that the air ventilation for
cooling is not obstructed.
A weld should join two work pieces as if they were made from a single piece. Prior to the welding the joints must
be cleaned and dirt, rust, grease and paint removed. Also slag from previous welds must be completely removed.
Attach earth clamp firmly to work piece, assuring good metal to metal contact. Check that all cables and
connectors are in proper operating condition to ensure proper current conduction.
Place electrode with the uncoated end into one of the electrode holder's notches. Each welding machine is
supplied complete with an accessory kit, comprising the welding cables, a welding visor and a slag hammer.
When removing slag it is recommended to protect the eyes by suitable means (goggles) from injury by sharp and
hot slag. The welding visor's dark glass plate protects the eye against ultra-violet and infrared rays. The clear
glass plate protects the dark plate against spatters and damage. The dark protective glass is available in different
shades for different types of electrodes and to suit different eye sensivity. Normally for electrodes from 1.5 mm
to 4 mm Ø protective glasses of shade DIN 9 are used, for electrode over 4 mm Ø shade DIN 10.
Select the correct welding current as shown below:
Current (A)
25 - 50
50 - 100
100 - 140
140 - 220
220 - 300
Electrode Ø
1.0 - 2.0 mm
2.0 - 2.5 mm
2.5 - 3.25 mm
3.25 - 5.0 mm
5.0 - 6.0 mm
Material Thickness
1.0 - 2.0 mm
2.0 - 4.0 mm
4.0 - 8.0 mm
8.0 - 12.0 mm
12.0 - 20.0 mm
In principle do not use too thick an electrode. As a general rule calculate 40 amps welding current per 1 mm of
electrode diameter. Depending on electrode type, material thickness and weld position this calculated value may
have to be adjusted to plus or minus. All machines work well with thin plate from 1.0 mm thickness.
3.1 Care of Stick Electrodes and their correct Use
In order to achieve a good weld the electrode has to be dry, thus storing in a dry place is essential- Should
electrodes have become moist, dry in an oven at between 200° C to 300° C for 30 minutes.
Basic coated low-hydrogen type electrodes always require pre-drying at 200° C to 300° C for 3 hours as atomic
hydrogen causes weld flaws.
The designation of welding electrodes is standardized by DIN 1913. The designation is stipulated by the
electrode manufacturers in accordance with the standard and checked by an inspection body. It is printed on
the electrode packet.
3.1.1Coding of Stick Electrodes according to DIN 1913
Example:
Stick electrode
DIN 913
-
E
43
3
2
AR
7
Type of electrode Number of DIN standard
Code for manual electric arc welding
Code number for tensile strength,
yield point and elongation
Code number for impact
engergy of 28 Joule minimum
Code number for increased impact
energy of 47 Joule minimum
Code for coating
Code number for electrode class
14
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3.1.2Function of the Stick Electrode Coating
Stabilization of the
arc and lonization
of the arc space
bare
electrode
coated
electrode
unstable
arc
stable
arc
Protection of the weld
metal from atmospheric
oxygen and nitrogen
bare
electrode
coated
electrode
shielding gas
slag
This protection is achieved by the generation of shielding gases and slag during the
melting of the electrode.
Compensation of alloy burn-off.
Stick Electrodes According to DIN 1913
D
D
D
Coating thickness
d
d
d
light
D = 1.2 · d
heavy
D > 1.55 · d
medium
D > 1.2 · d
<
=
but 1.55 · d
Material transfer
Gap bridging ability
Weld seam appearance
Penetration depth
Types of Coating
A
acid coated
R(C)
rutile cellulose medium coating
R
rutile light and medium coating
rutile heavy coating
rutile acid coating
cellulose coating
RR(C) rutile cellulose heavy coating
RR
AR
C
B
basic coating
B(R)
basic coating with non-basic proportions
RR(B) rutile basic heavy coating
15
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3.1.3Classification of Stick Electrodes
according to Table 3 of DIN 1913
Code for Welding Position
according to Table 4 of DIN 1913
Grade Stick Electrode
Type
Coating
Thickness
Weld
Position
Code
Weld Position
Code Letter For
Welding Position
w, h, hü, s, f, q, ü
A 2
R 2
1
2
3
all
2
1
2 (1)
1
light
all except vertical-down w, h, hü, s, q, ü
gravity position
fillet weld
gravity position
horizontal
gravity position
R 3
R(C) 3
w
3
medium
4
5
C 4
RR 5
RR(C) 5
RR 6
RR(C) 6
A7
AR 7
w
h
w
2
1
2
1
4
6
7
heavy
2
RR(B) 7
RR 8
RR(B) 8
B 9
B(R) 9
B 10
R(R) 10
RR 11
AR 11
B 12
8
1
2
9
10
11
12
(high-
performance
electrodes)
4 (3)
B(R) 12
3.1.4Selecting suitable Electrodes for a Welding Task
Welding Task
Stick Electrode Type
Component
out-of position
RR 6
welding of butt and RR 8
fillet welds on thin-
walled extrusion
horizontal or gravity RR 11
position fillet welds AR 11
on long beams with
"a" = 5 mm
gravity position
B 10
double-V welds on
thick plate tow bars
out-of-position fillet RR(B) 7
welds on bracket of RR(B) 8
10 mm thick plate
out-of-position butt weld 1:
welds on pipelines C 4
16
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Stick electrodes can be classified according to their coating as under:
Type Code
Type
Type of Slag
-
Penetration Depth
-
Electrode Manipula-
tion
Characteristics
Weld Appearance
Coating
Slag Removal Ability Gap Bridging Ability
Characteristics
O
minimal slag
shallow
-
excellent
more difficult to weld
than any other stick
electrode
very high deposition
rate, minimal heat
stress, little heat
distortion
convex, coarsely
rippled
Bare Electrode
finely distributed arc
stabilizers in the
electrode material
OO
minimal slag
average to deep
-
excellent
slightly easier to
weld than bare
electrodes
good deposition
rate, minimal heat
stress, little weld
distorition,
especially for root
welds
convex
-
coarsely rippled
Flux-CoreElectrode
arc stabilizers rolled
into the electrode's
core
N
porous, even slag
blanket
-
average
-
good to excellent,
depending on
coating thickness
weldability of fillet
welds improves with
increasing coating
thickness
general purpose
electrodes, for
steels sensitive to
welding conditions,
for thin plate
slightly convex to
flat, finely to
medium-coarsely
rippled
Titania Oxide Type
high contens of
titanium oxide
easily removed
Es
porous, even slag
blanket
deep
-
average
weldability of fillet
welds improves with
increasing coating
thickness
for steels sensitive
to welding
conditions, requires
good weld
flat, finely rippled
Acid-Coated Type
high contents of
heavy metal oxides
preparation
Ox
tight slag blanket of
evenly distributed
thickness
shallow
-
very poor
good weldability,
fillet welds in gravity
position only
for unalloyed low-
carbon steels,
requires good weld
preparation
concave, very finely
rippled
Iron Oxide Type
high contents of iron
oxides
-
very easily
Kb
Basic Low-
Hydrogen Type
high contents of
calcium or other
alkaline carbonates
thick slag blanket
-
fair
medium
-
good
handling requires
some practice, in
particular when
setting electrode to
and removing from
weld
particularly suitable
for thick plate and
rigid assemblies, for
high-carbon steels,
for thermo steels
slightly convex,
medium-coarsely
rippled
Ze
minimal, often
quickly solidifying
thin slag blanket
-
deep
-
very good
good handling as
only minimal slag,
heavy fume
for out-of-position
welding
slightly convex,
rippled
Cellulose Type
high contents of
organic components
generation
easy
In addition to the electrodes types shown in the above table there are several special types available coded SO. Cast
iron electrodes, for example, fall into this class.
When buying Kb and So type electrodes make sure they are suitable for AC current. As far as the quality grades are
concerned, a higher number indicates a better grade quality. For common low-carbon steels grades 7 - 9 are best
suitable.
The last letter of the code shown on the stick electrode indicates the coating thickness.
d
m
s
=
=
=
light coating
medium coating
heavy coating
17
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3.1.5Arc Starting and Arc Burning
Arc Strike
Always start the arc in the welding groove.
When the arc is stable weld over the arc strike and melt for good fusion, otherwise there is a risk of cracking.
Arc starting
sequence
d
a
wrong
arc strike
correct
arc strike
open-circuit voltage Short-circuit voltage working voltage
3 to 5 V 20 to 30 V
Arc Length
The arc length "a", that is the distance between the stick electrode and the work, should be:
with stick electrodes of coating type R, RR, A, C
with stick electrodes of coating type B
=
=
1.0xd,
0.5xd,
Too long an arc reduces the penetration, increases the arc blow effect and, particularly with basic coated stick
electrodes, causes a porous weld seam.
3.1.6Welding Positions According to DIN 1921
w
w
h
w = gravity position
h = horizontal position
f
ü
s
q
q = horizontal-vertical position
s = vertical-up position
ü = overhead position
f = vertical-down position
18
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4
Welding Hints
Because of the multitude of and great differences in the important points for welding only the very basic
operations for the most common electrodes for low-carbon steels, the Ti-type electrode, are introduced here.
In the case that other electrodes have to be used, the electrode manufacturers supply upon request all relevant
information for the type of special electrode to be used.
Always make some trial welds on scrap material. Select electrode diameter and welding current as per Table 1.
Attach earth clamp to work piece and place electrode into electrode holder as described earlier. Now hold the
electrode tip approx. 2 cm / 1 inch above the starting point of your welding seam. Hold the welding shield in front
of your face and draw the electrode with a short stroke along the groove. Through the welding shield you watch
the arc, keeping it to a length of 1 to 1.5 times the electrode diameter.
wrong
correct
arc too long
(Pic. 3)
approx. 1 - 1.5 the electrode-Ø
(Pic. 4)
Thecorrectarclengthisimportantforagoodweld, becausewithtooshortortoolonganarcbothweldingcurrent
and working voltage change. A low working voltage causes insufficient penetration. Too high or too low welding
current gives a poor welding seam. Too long an arc does not sufficiently melt the parent material, resulting in
high spatter losses. Also the air, with its detrimental substances like hydrogen and nitrogen, may get access to
the weld pool.
For a good weld the work angle of the electrode (or electrode inclination angle) is of substantial importance. The
inclination should be 70° - 80° to the welding direction. With the work angle too steep slag will run under the weld
pool, too flat an work angle causes the arc to spatter, in both cases the result is a porous, weak welding seam
(see pictures 5 - 7).
wrong
wrong
correct
welding direction
welding direction
welding direction
> 80°
70-80°
< 70°
(Pic. 5)
(Pic. 6)
(Pic. 7)
The welder has to keep the arc at the same length, that is the electrode burn-off is compensated by feeding the
electrode into the weld. At the same time the welder has to watch the weld pool for even penetration and width.
Welding is always done from left to right (backhand welding).
At the end of the welding seam the electrode can not simply be lifted or pulled from the weld, this creates porous
end craters, which weaken the weld. To correctly terminate a weld the electrode is held for a short moment at
the end of the weld seam, then lifted in an arc over the just laid weld.
wrong
correct
(Pic. 8)
Remove slag only after it has cooled down and is no longer glowing.
(Pic. 9)
If an interrupted weld is to be continued, the slag at the end of the already finished weld must be removed. Then
the arc can be started either in the groove or on the weld, as described earlier, and then moved to the end of
the weld, which has to be thoroughly melted for good fusion. Welding is then continued normally.
19
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4.1 Weld Types
For Butt Welds the work piece edges should be bevelled to approx. 30°, which gives a groove angle of 60°
(Pic. 10).
The root opening between the two work pieces should be 2 - 3 mm.
60°
(Pic. 10)
For Fillet Welds "a" is the throat width size. The throat width should be at least x 0.7 the plate thickness of the
thinner plate.
a
(Pic. 11)
Other weld types:
x-weld
y-weld
J-weld
Flange weld
A joint weld must always have a good fusion at the root.
wrong
correct
(Pic. 13)
(Pic. 12)
Let weld cool down in the ambient air, do not quench.
20
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4.2 Weld Flaws and possible Causes - Shown on Fillet Welds
End Crater
Weld Undercut
Electroderemovedtooquickly
fromtheweldpool,particularly
with high welding currents risk
of shrinkage cracking
Welding current to high
Electrodeworkangletoosteep
Arc too long
Slag Inclusion
Weld Toe Cracks
Material sensitive to welding
conditions
Weldcooleddowntoofastafter
welding
Welding current too low
Welding speed to high
Welding over slag on multi-
layer welds
Gas Inclusion
Work surface not clean
(rust, grease, paint)
Arc to long
Root Flaw
Basic coated electrodes not
sufficiently dried
Slag entering root area
because distance too great
5
Accessories and Accessory Maintenance
Connecting Welding Cables to the Welding
Power Source
Connecting (Extending) Welding Cables
Insulate screw joint terminal with rubber bush or heat-
shrinkable sleeve
Ring tongue terminal soldered, crimped, clamped
Fully Insulated Electrode Holder
Connection of Welding Cables to the Work Piece
spring
handle
hand lever
insulated jaws
Replace broken insulating parts at once!
Clean work piece surface for good conduction
Attach earth clamp as close as possible to the weld. Structural components, beams, pipes or rails should not be used
for earth conducting if they are not the actual work piece.
21
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6
6
6
6
Wiring Diagrams
Schaltpläne
Schémas électriques
Schakelschem
I
I I
N
L1
L2
Red Light
N
L1
L2
PE
CEE Plug
3P+N+PE
CEE Adapter
3P+N+PE
Plug
230 V
400 V
400 V 230 V
Schwitch Positions
Contacts
N - N
L1 - L1
L2 - L2
400 V
On
OFF
OFF
0
230 V
OFF
OFF
ON
ON
ON
ON
SB 160 C (230/400 V)
Thermo
switch
Control
light
N
Fan
L1
PE
240V
Transformer
240V
0
Voltage selector switch
SB 200 CT (240 V)
42
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I
I I
N
L1
L2
Red Light
N
L1
L2
PE
CEE Adapter
3P+N+PE
CEE Plug
3P+N+PE
Plug
230 V
400 V
400 V 230 V
Schwitch Positions
Contacts
N - N
L1 - L1
L2 - L2
400 V
On
OFF
OFF
0
230 V
OFF
OFF
ON
ON
ON
ON
SB 200 CT (230/400 V)
43
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