Chap.2 MMA Welding Power source - Cemont

CHAPTER 2MMA weldingpower sourcesIntroduction pages 2-2 & 2-3Inverter units■ SPEEDY II 130 / 150 page 2-5■ COLT 130G / 150G page 2-6■ PUMA S 1400 / S 1600 / S 1700G page 2-7■ PUMA SX 2200 GC page 2-8■ PUMA POWER 1700 / 2000 page 2-9■ PUMA 2000 XL page 2-10MMA WELDINGEQUIPMENTThree-phase DC rectifiers■ YARD SV 263 / SV 333 / SV 403 / SV 443 page 2-11Thyristor controlled units■ YARD 400 SX page 2-12■ YARD 650 SX page 2-13Options and accessories page 2-142-1

Duty cycleDefined by standard EN 60974-1Working cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 minutesAt ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 °CExample: 250 A at 60% means that in a temperature-stabilised cycle, the current sourcecan supply 250 A with a cycle of 6 minutes of welding and 4 minutes of stoppage.With a 100% duty cycle, the source of current can continuously supply the correspondingintensity with an ambient temperature of 40 °C.T1: Temperature of triggering by the thermal safety systemProtection index IPMeaning: IP 2 3 or231MMA electrodesMMA electrodes are made up of a metal wirecalled the core wire and a mineral coating.Role of the coating:• Encouraging electrode striking.• Protecting the deposited metal fromoxidation by the ambient air(formation of slag).• Controls the deposited metal mechanicalproperties.The two most common types of coating:• Rutile• BasicElectrode Ø (mm)2 1means that an object of more than 12.5 mmdiameter cannot enter or come into contactwith an internal element with a hazardous voltage.means that the current source is protected fromall damage during use by water falling at a maximumangle of 60°.means that the current source is protectedfrom vertical falling water.Thickness of material (mm)Recommended settingsTimeRutile electrodes:• These work with all typesof power source, using:- Alternating current (AC), if the open-circuitvoltage of the machine (Uo) is above65 V - 70 V.- Direct current (DC), if the electrode isconnected to the - pole.Basic electrodes:• Applications: Work requiring weldingmetal that needs to have high mechanicalcharacteristics, particularly toughness,i.e. resistance to impact and fracture at lowtemperatures.Current (A)Example: construction of bridges,wagons, structures, pressure devicesetc., all assemblies subject to highstress. The use of basic coatedelectrodes may require re-drying theelectrodes at 350 °C for two hoursin order to eliminate as much of themoisture in the coating as possible,which generates the release ofhydrogen during use, which can leadto cracking.LEXICONARC WELDINGHot Start:Makes striking easier withover-intensity upon startingup. It may be automaticor adjustable from thefront of the unit.Arc Force:Prevents sticking in thebath during welding.An electronic systemdetects abnormalcloseness between themetal core and the workpiece and providesextra energy to return tonormal conditions.U0 no-load voltage:That is the voltage betweenthe welding and earthterminals of the powersource. It must be greaterthan the electrode strikingvoltage (indicated on eachelectrode pack).Electrode efficiency:The addition of ironpowder to the coatingmakes it possible toincrease the efficiencyof the deposited metal.Example:• Electrode with conventionalcoating A 100-g coredeposits 100 g of bead.• Electrode with 120%efficiency A 100-g coredeposits 120 g of bead.Recommended settings:Formula for approximatingthe correct intensity settingdepending on the diameterof the electrodes:(Ø - 1) x 50 = Weldingintensity.Example: with an electrodewith a 2.5-mm diameter(2.5 - 1) x 50 = 75 A.MMA WELDINGEQUIPMENT2-3

The CEMONT offer, inverter technologyMMA WELDINGEQUIPMENTPUMA XL2000 XLPUMAPOWER1700POWER2000POWERPUMA GCSX2200 GCPUMA GS 1700GPUMA S S 1400 S 1600COLT 130G 150GSPEEDY II 130 150WeldingcurrentØ maxi. ofthe electrode125 A 130 A 150 A / 160A 180 A 220 A3.2 mm 4.0 mm 5.0 mmThe CEMONT offer, traditional technologyYARD STC400 SX 650 SXYARD SVWeldingcurrentØ maxi. ofthe electrodeSV 263 SV 333 SV 403 SV 443195 A 220 A 260 A 350 A 400 A 630 A4.0 mm 5.0 mm 6.3 mmSingle-phaseThree-phase2-4

MMA welding equipment.Inverter technology. 230 V single-phase input.SPEEDY II 130 / 1502WARRANTYYEARSMMA WELDINGEQUIPMENTThe new SPEEDY II power sources are theeasiest, the safest and the most convenientway to weld all types of MMA electrode.Dedicated for light duty and maintenanceactivities.■ Ultra-light portable equipment.■ Single-phase unit with 16 A“domestic plug“.■ Motor-generator compatible.■ IPM technology (Inverter PowerMicrocontroller) makes itextremely easy to use forwelding in all positions.■ For electrodes up todiameter 3.2 mm(SPEEDY II 150).Features and product advantages:■ Complete packaging■ Safe and reliable■ Excellent starting and arc stability dueto the IPM technology with Arc Forceand Hot Start linked to the weldingcurrent. Easy to use and high quality■ Single-phase 230 V unit■ Extra light: < 3.8 kgTECHNICAL CHARACTERISTICS:SPEEDY II 130 SPEEDY II 150Single-phase input voltage 230 V - 50/60 Hz - +/- 10%Input power 6.8 kVA - 4 kW 8 kVA - 4.8 kWMax input current 30 A 35 AEffective input current 10 A 11 AOpen circuit voltage69 VWelding current range 10 - 130 A 10 - 150 ADuty cycle at 10% 130 A 150 Aat 40°C at 60% 60 A 70 A(EN 60974-1)at 100% 45 A 55 AConnector size9 mmProtection index IP 21DimensionsWeight2012-5282012-521MOTOR GENERATORCOMPATIBLE12220 x 120 x 320 mm3.8 kgINVERTER POWERMICROCONTROLERI.P.M. TECHNOLOGY32012-610123NEWPower potentiometer.Warning light.Switch on/off.Delivered equipped with:■ Power sourcewith primary cableequipped with a 16 Aschuko plug■ Electrode holderand earth clamp withcables and connectors■ Brush/Chippinghammer■ Electrode small pack(rutile coating)■ Safety instructions anduser manual■ CaseStandardsEN 60974-1EN 60974-10MMA WELDING EQUIPMENTMMA WELDINGEQUIPMENTTO ORDER:Complete packaging W000373605 W0003736042-5

MMA welding equipment.Inverter technology. 230 V single-phase input.COLT 130G / 150GThe range of COLT power sources, known all around the world for itsexceptional power to weight ratio, now with full generator compatibilitydue to its new I.P.M. technology (Inverter Power Microcontroller).This professional range is suitable for light duty and maintenance activities.Features and product advantages:■ Compatible with motor-generators.■ Delivered ready to use in a plastic case with all accessories:Plug & Weld.■ Compatible with use in the domesticenvironment due to reduced electromagneticemissions: the cleanest unit in its category.■ 2 years warranty. Safe and reliable.■ Excellent starting and arc stability due tothe IPM technology with Arc Force andHot Start linked to the welding current.Easy to use and high quality.■ Single-phase 230 V unit,extra light: < 3.8 kg.2WARRANTYYEARSULTRA-MOBILEREADY TO USEMMA WELDINGEQUIPMENTStandardsEN 60974-1EN 60974-10MOTOR GENERATORCOMPATIBLE2008-713_retTECHNICAL CHARACTERISTICS:Single-phase input voltageCOLT 130G230 V - 50/60 HzCOLT 150GInput power 6 kVA - 3.5 kW 7.45 kVA - 4.5 kWMax input current 30 A 31 AEffective input currentOpen circuit voltage12 A69 VWelding current range 10 - 120 A 10 - 140 ADuty cycle at 15% 120 A 140 Aat 40 °C at 60% 60 A 70 A(EN 60974-1)at 100% 45 A 55 AConnector size9 mmProtection index IP 23Dimensions220 x 120 x 320 mmWeight 3.5 kg 3.8 kgTO ORDER:Power sourcecomplete with coseW000271548W000271547Delivered equipped with:■ primary cable,Accessoriessee page 2-16■ welding cable with electrode holder,■ welding cable equipped with earth clamp,■ hammer / brush / helmet,■ pack of rutile electrodes,■ safety instructions,■ user manual,■ PVC case for transportation.2-6

MMA welding equipment.Inverter technology. 230 V single-phase input.PUMA S 1400 / 16001700GThe PUMA power sources are for MMA coated electrode weldingfor both industrial and daily use.A special version compatible with generators is available (1700G).The PUMA range has been designed for on site use.Features and product advantages:■ Light weight: less than 7 kg.■■■■Versatile: able to weld all types of MMAelectrodes (steel / stainless steel etc…).User friendly: Hot Sart / anti-stick device.Powerful: high duty cycle at 40 °C.Transportable: using the shoulder strap.■ Generator compatability only PUMA 1700G.2WARRANTYYEARSHEAVY DUTYMMA WELDINGEQUIPMENTStandardsEN 60974-1EN 60974-10MMA WELDING EQUIPMENTMMA WELDINGEQUIPMENT3122006-6162006-614123Power potentiometer.Switch on/off.Warning light.TECHNICAL CHARACTERISTICS:PUMA S 1400 PUMA S 1600 PUMA S 1700GSingle-phase input voltage230 VInput power 6.5 kVA - 4 kW 7.3 kVA - 4.6 kW 7.3 kVA - 4.6 kWMax input current 25.5 A 31 A 31 AEffective input current 15 A 16 A 19 AOpen circuit voltage85 VWelding current range 5 - 130 A 5 - 150 A 5 - 150 ADuty cycle at 35% 130 A 150 A (25%) 150 Aat 60% 100 A 120 A 120 Aat 100% 80 A 100 A 100 AConnector size9 mmProtection index IP 23Dimensions145 x 230 x 365 mmWeight7 kgTO ORDER:Power source only W000263627 W000263636 W000263650Accessoriessee page 2-16Delivered equipped with:■ primary cable,■ safety instructions,■ user manual.2-7

MMA welding equipment.Inverter technology. Cellulosic applications.PUMA SX 2200 GCThe PUMA SX family is specially designed for heavy duty applicationsand features new functions such as the advanced TIG LIFT mode withcontrol of slope up and down (SX 2200 GC). The digital display allowsthe setting of Arc dynamism for improved arc stability in all weldingapplications. The GC range is an industrial range, compatiblewith the use of motor-generators and for welding with all typesof MMA electrodes including cellulosic.Features and product advantages:■ Compatible with motor-generators.■ 2 years warranty. Safe and reliable.Cellulosic Applications■ Digital display: precise adjustmentand reading of the parameters (SX 2200 GC).■ Comfortable: over-intensity when startingand anti-stick device(adjustable on SX 2200 GC).■ Suitable for welding with cellulosic electrodes.2WARRANTYYEARSMMA WELDINGEQUIPMENTStandardsEN 60974-1EN 60974-102006-68212345672006-8611234567Remote control plug.Alarm indicator.Current output indicator.Welding Process Selection Key.Parameter display .Welding parameter selection key.Parameter adjustment.TECHNICAL CHARACTERISTICS:PUMA SX 2200 GCInput voltage 50/60 Hz400 V Three-phaseInput power9.8 kVA - 7.2 kWMax input current14.2 AEffective input current9 AOpen circuit voltage105 VWelding current range5 - 220 ADuty cycle at 30% 220 A (40%)at 60%190 Aat 100%150 AConnector size13 mmProtection index IP 23Dimensions180 x 250 x 400 mmWeight8 kgAccessoriessee page 2-16TO ORDER:Delivered equipped with:Power source onlyOptionRemote controlW000263688W000242069■ primary cable,■ safety instructions,■ user manual.2-8

Coated electrode and TIG DC (TIG lift)arc welding stationSingle-phase power supply.PUMA POWER1700 / 2000Improved performance:■ Higher duty ratio (180 A - 20% / 160 A - 30%).■ Better compatibility with the generators thanksto the POWER controller.■ Long primary cables (70 m – diameter of 2.5 mm 2 ).■ Excellent priming, Hot Start, Anti-adhesion.■ Welding of all types of electrodes (except cellulosic).TECHNICAL CHARACTERISTICS:PUMA 1700POWERPUMA 2000POWERPRIMARYPower supply230 V single-phaseFrequency50/60 HzInput power 4.9 kVA - 4.85 kW 5.7 kVA - 5.65 kWMax input current 21.5 A 25 AEffective input current15 ASECONDARYOpen circuit voltage48.4 VWelding current range 5 A - 160 A 10 A - 180 Aat 20% - 180 Aat 30% 160 A -Dutyat 40% - -cycleat 60% 140 A 140 Aat 100% 120 A 120 AProtection class IP 23Insulation classHWeight6.6 kgDimensions170 x 320 x 395 mmTO ORDER:Power source only W000274931 W000270335Equipped version* W000278051 W0002750412WARRANTYYEARSMOTOR GENERATORCOMPATIBLEReduced consumption:■ Uses a 16 A socket.■ All the models comewith a standard socket.Superior ergonomics:■ Silent: “intelligent fan”.■ Light: only 9 kg.■ Compact design.Class ASAVE ENERGY2009-484THE TECHNICALSOLUTIONRESPECTINGTHE LIMITATIONOF HARMONICSDelivered equipped with:■ power cable,■ safety, user andmaintenance manual.* Equipped versionalso with:■ cable, earth clamps,electrode clamps andfittings.MMA WELDINGEQUIPMENTStandardsEN 60974-1EN 60974-10Accessoriessee page 2-16MMA WELDING EQUIPMENTMMA WELDINGEQUIPMENTThe standard EN 61000-3-12 applicableto welding equipment in December 2010,limits the harmonic current of equipmentconnected to the low voltage mainssupply (CEM).Public networkHigh voltageIndustry connected tothe high voltage supplyLocal transformerNo limit to thecurrent harmonicsCLASS A necessaryPublic networkAverage voltageHouse connected tolow voltage supplyNo local transformerCLASS BobligatoryLimit applicable tocurrent harmonicsPublic networkLow voltageIndustry connected tothe low voltage supplyNo local transformerLimit applicable tocurrent harmonicsCLASS Anecessary2-9

PUMA 2000 XLImproved performance:■ Higher duty ratio (160 A at 50%).■ Better compatibility with the generators thanksto the POWER controller.■ Long primary cables (70 m - diameter of 2.5 mm 2 ).■ Excellent priming, Hot Start, Anti-adhesion.■ Welding of all types of electrodes (cellulosic).■ Equipped with the VRD (Voltage Reduction Device)for improved safetyReduced consumption:■ Uses a 16 A plug.■ This model come witha standard plug.Coated electrode and TIG DC (TIG lift)arc welding equipmentSingle-phase power supply.2WARRANTYYEARSTHE TECHNICAL SOLUTIONRESPECTING THE LIMITATIONOF HARMONICSMMA WELDINGEQUIPMENTStandardsEN 60974-1EN 60974-10Superior ergonomics:■ Silent: “intelligent fan”.■ Light: only 9 kg.■ Compact design.SAVE ENERGY2010-076MOTOR GENERATORCOMPATIBLEClass ATECHNICAL CHARACTERISTICS:PUMA 2000 XLPRIMARYMMATIGPower supply230 V single-phaseFrequency50/60 HzInput power4.8 kVA - 4.78 kWMax input current 21 A 14 AEffective input current 16 A 11 ASECONDARYOpen circuit voltage75 VVRD no load voltage14 VWelding current range5 A - 160 Aat 50% 160 A -Duty cycleat 60% 150 A 160 Aat 100% 130 A 130 AProtection classIP 23SInsulation classHWeight9 kgDimensions185 x 300 x 435 mmTO ORDER:Power source onlyEquipped version*W000271808W000278048Accessoriessee page 2-16Delivered equipped with:■ power cable,■ safety, user and maintenance manual.* Equipped version also with:■ cable, earth clamps, electrode clampsand fittings.2-10

YARD SV 263 / SV 333SV 403 / SV 443YARD power sources are rectifiers for MMA coated electrodewelding. They are well suited for both workshop and outdoorworking conditions. Easy to use with adjustment using theshunt, they are for professional and intensive applications.Features and product advantages:■ Input voltage: bi-tension 230 V - 400 V three-phase.■■■■■Simple: power adjustment by shunt.Easy to set: linear control.Cooling: forced air cooling fan.Practical: due to the large diameter wheelsand handle.Versatile: able to weld all typesof electrodes (including cellulosics).MMA welding equipment.Transformer technology.Three-phase input voltage.POWERFULROBUST2WARRANTYYEARSMMA WELDINGEQUIPMENTStandardsEN 60974-1EN 60974-10MMA WELDING EQUIPMENTMMA WELDINGEQUIPMENT132006-927242006-9251234Switch on/off and primaryvoltage selection.Current adjustment.Welding current indicator.Welding cables connectors.TECHNICAL CHARACTERISTICS:Three-phase input voltageYARD SV 263 YARD SV 333 YARD SV 403 YARD SV 443230 - 400 V triphaséInput power 14.5 kVA - 8 kW 16.9 kVA - 10 kW 22.8 kVA - 13 kW 31.2 kVA - 18 kWMax input current 36 A - 21 A 43 A - 25 A 57 A- 33 A 78 A - 45 AEffective input current 21.5 A - 12.5 A 25 A - 15.5 A 34 A - 19.5 A 52 A - 30 AOpen circuit voltage 62 V - 66 V 61 V - 66 V 63 V - 70 V 71 V - 79 VWelding current range 45 - 220 A 55 - 260 A 50 - 325 A 60 - 400 ADuty cycle at 35% 220 A 260 A 325 A 400 A (45%)at 40 °C at 60% 170 A 200 A 250 A 345 AConnector sizeat 100% 130 A 155 A 190 A 265 A13 mmProtection index IP 21Dimensions (mm) 450 x 620 x 890 560 x 730 x 1080Weight 57 kg 83 kg 107 kg 123 kgTO ORDER:Power source only W000263691 W000263693 W000263695 W000263696Accessoriessee page 2-16Delivered equipped with:■ primary cable,■ safety instructions,■ user manual.2-11

Coated electrode welding station.Thyristor technology. Three-phase power supply.YARD 400 SXThe YARD 400 SX station was designed using thyristortechnology, internationally recognized as strong, high performingand reliable. The YARD 400 SX has already been tested in all kindsof field such as the manufacture of transport equipment, navalconstruction, repair, etc. The YARD 400 SX is ideal for intensive workwith coated electrodes (cellulosic types included) and for gouging.Features and product advantages:■ Power supply: dual-voltage 230 / 400 V three-phase.■ Intensity regulation: electronic.■ Display: digital A / V.■ Versatility: EE / TIG DC / Gouging.■ Flexible: possibility of modifying the Hot Startand arc dynamism.■ Professional: steel structure on wheels, retractablebeams and lifting rings.■ Remote control: easy control at a distance.2010-234INTENSIVEVERSATILE(electrode/gouging/TIG DC)MMA WELDINGEQUIPMENTStandardsEN 60974-1014 62352010-234123456on/off switch andprimary voltage switch.Control knob.A/V digital display.EE/TIG control.Hot Start/Arc dynamism regulation.Connector for remote control.TECHNICAL CHARACTERISTICS:YARD 400 SXPower supply230 - 400 V three-phase +/- 15% 50/60 HzInput power26 kVA - 20 kWMax input current69 A - 40 AEffective input current40.6 A - 23.5 AOpen circuit voltage68 V - 75 VWelding current range10 - 400 ADuty cycleat 40 °CSize of connectorat 35%400 Aat 60 %300 Aat 100%230 A13 mmElectrode diameter1.6 to 6.3 mmProtection class IP 23Dimensions1000 x 600 x 600 mmWeight128 kgTO ORDER:09692420388Remote controlAccessoriessee page 2-16Power source onlyEquipped version*OptionRemote controlOption 42 VVRDTIG caseW000272668W000275044W000219557W000260682W000275160W000305050Delivered equipped with:■ primary cable,■ safety, user and maintenance manual.* Equipped version also with:■ cable, earth clamp, electrode clampand fittings.2-12

YARD 650 SXMMA welding equipment.Transformer technology.Three-phase input voltage.2WARRANTYYEARSMMA WELDINGEQUIPMENTThe new YARD 650 SX uses electronic regulation for control of the welding current.Designed for adverse conditions, the YARD 650 SX is reliable and sturdy, dedicatedto heavy duty applications from steel construction to shipyards.An 8-bit processor controls the welding process, protectsthe equipment and informs the welder of the current state.The YARD 650 SX is the solution for MMA welding,TIG lift welding and ARCAIR gouging.Features and product advantages:■ Digital display for precise parameter regulation and monitoring.■ Process selector: MMA, TIG lift, gouging, MIG/MAG welding.■ 42 V DC current up to 150 A available.■ 48 V AC auxiliary current available as an option(up to 32 A).■ Remote control (option).■ Compensation of input voltage variations.■ Hot start and Arc Force regulation availablefor improved arc starting and stability.MULTI PURPOSEAPPLICATIONSROBUST ANDPOWERFULStandardsEN 60974-1EN 60974-102008-786MMA WELDING EQUIPMENTMMA WELDINGEQUIPMENT123452008-7871 Switch on/off and primary 3 Digital display A/V.voltage selection. 4 Hot Start / Arc Force adjustment.2 Regulation knob.5 Remote control connection.TECHNICAL CHARACTERISTICS:Three-phase input voltageInput powerMax input currentYARD 650 SX230 V - 400 V - 50/60Hz40 kVA - 38 kW102 A - 60 AEffective input current 61.5 A (230 V) - 35.4 A (400 V)Open circuit voltageWelding current range68 V - 75 V10 A - 630 ADuty cycle at 35% 630 Aat 40 °C at 60% 470 AConnector sizeat 100%370 A13 mmProtection index IP 23DimensionsWeight1000 x 600 x 600 mm176 kgAccessoriessee page 2-16TO ORDER:Power source onlyW000272669OptionRemote controlW00021955748 V socket for auxiliary services W000260682Delivered equipped with:■ primary cable,■ safety instructions,■ user manual.2-13

Options and accessories for MMA.MMA WELDING KIT (ELECTRODE HOLDER + EARTH CLAMP)MMA WELDINGEQUIPMENTACCESSORIES KITSName 16C25 25C25+ 35C50 50C50 50C50+Connector size Ø 9 mm 2 Ø 9 mm 2 Ø 13 mm 2 Ø 13 mm 2 Ø 13 mm 2COLT* W000260680 - - - -PUMA - W000011138 - - -PUMA POWER - - W000268854* - -PUMA SX / YARD SV 263 - - W000011139 - -PUMA XL - - W000268856* - -YARD SV - - - W000260681 -YARD 400SX / YARD 650SX - - - - W000260682* with welding mask + hammer and brush2009-163MMA OPTIONS:COLT PUMA PUMA SX YARD SXRemote control - - W000242069* W000215557TIG torch with valveWTT2 9V 4 mWTT2 26V 4 mW000278878W000278885* PUMA SX 2200 GC only2010-6862-14