TER 206, Operating Manual

Page 1: ...OPERATING MANUAL Inglese GB GB TER 206 SERIES This manual must be completed by the CE Operating and service maual Edition of 29 07 2015 Rev 00 ...

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Page 3: ...ard 2006 95 CE LDV 2004 108 CE EMC 2002 95 RoHs and with the instructions contained in the harmonized standard if applicable EN 60974 1 EN 60974 2 EN 60974 3 EN 60974 5 EN 60974 7 EN 60974 10 EN 60974 12 Date 31 01 2012 Maurizio Terzo General Manager IN CASE OF BAD OPERATIONYOU DEMAND THE ATTENDANCE OF QUALIFIED STAFF The equipment don t compiles with EN IEC 61000 3 12 The installer or the user mu...

Page 4: ...ling of this product For more detailed information about recycling of this product please contact your local city office your household waste disposal service or the shop where you purchased the product 2 SAFETY PRECAUTIONS WELDING AND ARC CUTTING CAN BE HARMFUL TO YOURSELF AND OTHERS The user must therefore be edu cated against the hazards summarized below deriving from welding operations ELECTRI...

Page 5: ... of vital electronic equipment pacemakers should consult their physician before beginning any arc welding cutting gouging or spot welding operations EXPLOSIONS Do not weld in the vicinity of containers under pressure or in the presence of explosive dust gases or fumes All cylinders and pressure regulators used in welding operation should be handled with care 3 General description This machine is a...

Page 6: ...dustrial power sources for light medium applications the duty cycle is very high and the design of the power inverter allows hight current rates When the machines are connected to the domestic house power supply a plug 16A should be mounted the input current must be less than average 16A in order to avoid the switching off of the main switch protecting the power line The PLC feature controls the i...

Page 7: ...ations and the green ones are for domestic with the PLC key turned in 16A position MIG PULS MIG PLC 0 1 1 10 100 1000 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 CURRENT ELCTRODE PLC 0 1 1 10 100 1000 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 CURRENT TIG TIG PULSE PLC 0 1 1 10 100 1000 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 CURRENT ...

Page 8: ...elding the current supply is breaked immediately and the front panel shows the PLC timer count down When the timer arrive to 0 the welding can restart Please refer to the plots in order to avoid unexpected welding interruptions when the machine is used on dome stic lines ...

Page 9: ...ion is active with an output no load voltage equal to 15V When VRD feature is off an icon led shows voltage greather than 25V Setting when VRD is off press the CYCLE pushbutton for 7 seconds once the VRD led start flashing release the button pressure when VRD is on press the CYCLE pushbutton for 7 se conds until the VRD icon ligth off In the meantime the icon U2 25LV should light on The machine st...

Page 10: ...ally doesn t work Power supply control The machine can be used with motogenerator power supply and or long supply cables the supply voltage should run between 180V and 270V limits When the supply voltage overlaps those limits the machine functions stop and the main panel lights the last sup ply voltage like picture shows Functions can be recovered switching the machine off and than on again STAND ...

Page 11: ...ct the electrode holder and the earth clamp plugs to the correct machine polarities according to the electrode manufacturer specs Negative polarity Positive polarity Press the first pushbutton and select the icon STICK Press the second pushbutton and select icon MANUAL ...

Page 12: ...have a soft dynamic close to 0 basic and the majority of the industrial electrode applications need a medium dynamic 10 12 while cellulosic needs a high one Setting Press the second level pushbutton the icon HS lights and its value appears on the display The icon flash for two seconds and durig this time pressing the pushbuttons and adjust the value Two seconds after the last touching the display ...

Page 13: ... electrode unstick Once active the Antisticking icon flash on the front panel ANTISTICKING Any setting in the MMA stick manual mode once fixed is considered like a user program it means once the user select the stick manual mode again the last adjustment is recovered and proposed Again if the machine is turned off for any reason the last mode and setting are proposed in the front panel ...

Page 14: ...l solution to approach the MMA welding avoiding setting mistakes Even professional welders can use the synergic mode in order to approach faster new settings Press the first pushbutton and select the icon STICK Press the second pushbutton and select the material type With the third pushbutton select the electrode diameter ...

Page 15: ...thickness values equivalent thickness equivalent thickness ARC DYNAMIC It is already set with an optimal value according to the choosed basic material and electrode but it can be adju sted as shown on chapter The dynamic of the arc The adjustment works in value over the program setting Dynamic icon selected Increase dynamic by 15 Once settings are given they are stored as default programs for MMA ...

Page 16: ...t the auxiliary plug if the machine is provided with the remote control socket Connect the torch gas hose to the output nipple if the machine is equipped with gas control Connect the argon gas bottle to the input gas nipple located on the machine back side and adjust the gas flow between 5 to 7 liters per minute ...

Page 17: ...the gas flow Slow down the torch until the ceramic nozzle touch the workpiece in this phase held the torch and avoid any contact between tungsten and workpiece Keeping the nozzle in contact turn the torch until the tungsten enters in contact with the workpiece Maintaining the nozzle work piece contact turn back the torch to the original position the arc strikes and the welding can be performed ...

Page 18: ...he high frequency impulse stops after 4 seconds Drive again the torch switch In particular environment conditions such as hospitals aerports active nuclear plants etc the high frequency should be forbitten In that case deselect the high frequency and use only lift arc start Press and pushbuttons to select or deselect the high frequency mode Press the second level pushbutton up to the icon HF flash...

Page 19: ...CURRENT SETTING Manual Press the first pushbutton and select TIG or TIG PULSE Press the second pushbutton and select MANUAL With the third pushbutton select the electrode diameter Set with pushbuttons or the required welding current ...

Page 20: ...st torch switch pressure slope rise up releasing the torch switch Down slope to current I3 at second switch pressure and stop with switch release NOTES In manual tig setting certain parameters can be adjusted by the user while others are fixed PREGAS fix at 0 1 sec UP slope automatic depending from down slope CURRENT 1 initial current fixed CURRENT 3 craterfiller final current fixed DOWN slope var...

Page 21: ...select the material type With the third pushbutton select the tungsten size Set with pushbuttons or the required wel ding current Current level limits depend from the choosed program The basic material thickness setting is strictly connected with the selected current and material type ...

Page 22: ... STEPS SLO PE The current starts at level 1 at the first torch switch pressure slope rise up releasing the torch switch Down slope to current I3 at second switch pressure and stop with switch release NOTES In synergic tig setting all the parameters change according to program and current PREGAS fix at 0 1 sec UP slope automatic depending from down slope CURRENT 1 automatic sinergic CURRENT 3 autom...

Page 23: ...s are allowed chan ging the program values Press the second level pushbutton up to the icon SLOPE DOWN ligth on than adjust the parameters between 50 and 50 by pressing pushbutton or Press the second level pushbutton up to the icon POST GAS ligth on than adjust the parameters between 50 and 50 by pressing pushbutton or Follow the same procedure for frequency ...

Page 24: ...ATING MANUAL English GB GB Connect the gas bottle to the back side gas input nipple The mig and puls mig versions include the second connector for spool on gun fitting Select mig MIG WELDING machine setting ...

Page 25: ...s mig Connect the spool on gun main cable to positive or negative po larity according to the wire type ex innershield wire must be con nected to the negative polarity Connect the auxiliar connector and the gas hose SPOOL ON GUN CONNECTION ...

Page 26: ...GB Held the spool and insert a wire portion up to the driving rools of the gun Insert the spool into the spool holder and brake it fixing the shaft clockwise Press the torch switch the wire should carried out up to the tip orifice ...

Page 27: ...OPERATING MANUAL English GB GB Unlock the machine Open the machine toward the right side FEEDER 6K CONNECTION ...

Page 28: ...G MANUAL English GB GB Check if the driving rolls match the appropriate wire diameter Push the wire between the driving rolls up to see it outsi de the Euro torch connector Close the upper rolls with the shaft ...

Page 29: ...OPERATING MANUAL English GB GB Connect the mig gun ...

Page 30: ...OPERATING MANUAL English GB GB Close the machine and connect the main cable to positive or negative polarity Connect the workpiece cable ...

Page 31: ... drives out slowly for 5 seconds than stops and the frontal panel shows inc 10 that means the state of inch wire is active Release the switch and push it again The wire will drive out continuosly at a speed of approx 10 meters min until the switch remain pressed ...

Page 32: ...OPERATING MANUAL English GB GB Press the first pushbutton Select MIG Press the second pushbutton Select MANUAL MIG SETTING Manual mode ...

Page 33: ...OPERATING MANUAL English GB GB Set the welding voltage pressing the and pushbuttons Press the second level pushbutton the icon WIRE SPEED flash to show it s waiting for input data ...

Page 34: ...OPERATING MANUAL English GB GB Set the wire speed pressing the and pushbuttons If the and pushbuttons aren t driven the setting come back to the voltage adjustment and the icon WIRE SPEED stops to flash ...

Page 35: ...ATING MANUAL English GB GB Select the cycle first icon is spot welding TIMER Second icon is two steps cycle Weld when the gun switch remain pressed Post gas can be adjusted with the second level pushbutton ...

Page 36: ...s the pregas protection once the switch is released the welding starts and it stops at the second switch press The gas flow continue unti the switch is totally released Forth icon is two step with down slope when the switch is released the current slow down to final current with down slope ...

Page 37: ...h is totally released At the second press the current slow down to the final current with slope adjustable with second level pushbut ton Note during the welding the icon V SET blank and ligh on the icon I REAl the main digital instrument shows the real welding current Press for 5 seconds the second level pushbutton The main display write BBT and the right hand side display will show the actual BBT...

Page 38: ...he BBT with and pushbuttons and try the new value in welding Once the final setting is done press the second level pushbutton again back to the main setting menù Press the second pushbutton Select the material type MIG SETTING Synergic mode ...

Page 39: ...OPERATING MANUAL English GB GB Press the third pushbutton Select the wire diameter Set the welding current controlling the workpiece thickness or viceversa ...

Page 40: ...OPERATING MANUAL English GB GB Press the second level pushbutton to light the arc length icon on Adjust the arc length pressing the pushbuttons and ...

Page 41: ...st the inductance pressing the pushbuttons and Note in the synergic setting mode all the welding parameters are pre set according to the chosed program and the current setting The inputs related to arc length inductance bbt post gas slope initial and final current strictly depend from pro gram and current settings ...

Page 42: ...OPERATING MANUAL English GB GB Press the first pushbutton Select PULS MIG Press the second pushbutton Select the material type PULS MIG ...

Page 43: ... MANUAL English GB GB Press the third pushbutton Select the wire diameter and the proper gas 1 Argon 2 Mix 85 15 3 Mix 92 8 4 935 2 5 98 2 Set the welding current controlling the workpiece thickness or viceversa ...

Page 44: ... length icon on and adjust the arc length pressing the pushbut tons and Press twice the second level pushbutton to ligth the icon of the inductance on and adjust the inductance pressing the pushbuttons and increase inductance value for softer arc and reduce it to obtain a harder arc ...

Page 45: ... socket 1 for Tig MMA applications Use socket 2 for Mig Pulsed Mig and Spool on gun applications Important do not use the machine with both sockets connected REMOTE CONTROL Note once the remote control plug is connected the icon I SET will flash and the display will show the remote control set value From the machine potentiometer it is possible to adjust the maximum setting current The display sho...

Page 46: ... At the power on the display show wich device selected rLF means the external wire feedre rLF selected SPG means the SPOOL GUN torch selected selection device procedure press and hold the selection switch as picture untill display show the selected devce by the switch change device rLF or SPG confirm selection by switch selection switch ...

Page 47: ...SYNERGIC PROGRAMS PULS MIG SYNERGIC PROGRAMS SG2 0 6 SG2 0 8 SG2 0 8 SG2 0 9 SG2 0 9 SG2 1 0 SST 0 6 SST 0 8 SST 0 8 SST 0 9 SST 1 0 AlMg5 0 6 AlMg5 0 8 AlMg5 0 9 AlMg5 1 0 AlMg5 1 0 AlMg5 1 2 CuSi 0 8 CuSi 0 8 CuSi 0 9 CuSi 1 0 Albz8 0 8 flux 1 0 flux 1 2 shield 0 9 ...

Page 48: ...TORCH REMOTE CONTROLL CONNECTION DIAGRAM ...

Page 49: ...TER 206 MACHINE SCHEMATICS 1 ...

Page 50: ...matics 1 T166PCB POWER CONTROL BOARD PCB1 2 T206PCB MIG MOTOR DRIVER BOARD PCB3 3 T170PCB CONTROL PANEL BOARD PCB2 4 B0035AA FEMALE PANNEL CONNECTOR 7 POLES X7 X3 5 C0508AA CPNTRL PANEL PLEXY PÈROTECTION TER 206 spare parts 2 3 4 5 ...

Page 51: ...wire feeder WF206 spare parts nr code description rif schematics 1 A0026AA SSJ 15 MOTOR FEEDER MOT1 1 ...

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Page 53: ...EXTERNAL WIRE FEEDER MACHINE SCHEMATICS ...

Page 54: ...rnal wire feeder LRF spare parts nr code description rif schematics 1 A0027AA SSJ 4D MOTOR FEEDER MOT1 2 B0276AA SWITCH COM1 3 E0133AA 5KHOM POTENTIOMETER POT1 4 D0250AA KNOB FOR POTENTIOMETER POT1 1 3 2 4 ...

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Page 56: ...OPERATING MANUAL English GB GB Ter srl Via Giacomo Leopardi 13 36030 Caldogno VI ITALY Ph 39 0444 586440 Fax 39 0444 905764 e mail info terwelding com ...