AES Masterweld 204T, Instruction Manual

Page 1: ...Cod 006 0001 1439 13 05 2013 v2 4 ENGLISH MASTERWELD 204T Instruction manual GB ...

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Page 4: ...A 15 Remote control activation 15 Spot welding time 15 HF arc strike enable 15 Minimum pedal current 15 Q Start 15 Dynamic Arc 15 Multi Tack 15 11 1 PARAMETERS ACTIVATION 16 12 WELDING SETTINGS 17 12 1 ELECTRODE WELDING MMA 17 12 1 1 MMA PARAMETERS SETTING 1ST LEVEL 17 12 1 2 MMA PARAMETERS SETTING 2ND LEVEL 17 12 1 3 MMA SPECIAL FUNCTIONS 18 12 2 DC TIG WELDING 18 12 2 1 DC TIG PARAMETERS SETTING...

Page 5: ...ental sticking Up to 4 00mm diameter electrode welding is possible in MMA The power source is designed to guarantee safety and flexibility through the following features OVERCUT in case of over voltage in the supply line the supply to the power source is cut off The overcut protection protects electronic parts of the machine against damage caused by voltage surges CURRENT AUTO CALIBRATION the powe...

Page 6: ...disconnect the various devices with the machine switched off 4 2 PREPARING FOR MMA WELDING 1 Set the welding power source ON OFF switch to O unit de energized 2 Plug the power cable plug into a mains socket outlet 3 Choose the electrode based on the type of material and thickness of the workpiece to be welded 4 Insert the electrode in the electrode holder 5 Connect the electrode holder clamp plug ...

Page 7: ...the TIG torch 9 Connect the earth clamp plug to the following welding socket Positive pole welding socket 10 Connect the earth clamp to the workpiece being processed 11 Set the welding power source ON OFF switch to I unit powered 12 Select the following welding mode on the user interface DC TIG 13 Press the torch trigger with the torch well clear of any metal parts This serves to open the gas sole...

Page 8: ... High frequency arc strike HF L9 Illuminates to show a value in the following unit of measurement KILOHERTZ L10 Illuminates to show a value in the following unit of measurement AMPERES L11 Illuminates to show a value in the following unit of measurement VOLTS L12 When this LED illuminates the following parameter can be set ELECTRODE TYPE L13 DC TIG mode Illumination shows that the following functi...

Page 9: ...eters are automatically regulated by the machine The synergy is optimised by angle welding D1 Parameters functions setting The display shows the selected parameter Welding The display shows the effective amperes or volts value during welding HOLD function The display shows the current of voltage average values of the last welding process E1 Parameters functions setting The encoder provides the fac...

Page 10: ... on SUPPLY VOLTAGE CURRENT RANGE THAT CAN BE SET MMA CURRENT RANGE THAT CAN BE SET TIG 115 V 15 50 60 Hz 10 A 115 A 5 A 115 A 230 V 15 50 60 Hz 10 A 180 A 5 A 200 A 7 RESET LOAD FACTORY SETTINGS The reset procedure involves complete restoration of the default values parameters and memory settings set in the factory All memory locations will be reset and hence all your personal welding settings wil...

Page 11: ...ode 3 This setting enables fast pulsed mode Cooler activation ON The cooler is always running when the power source is switched on This mode is preferable for heavy duty and automatic welding procedures OFF The cooler is always disabled because an air cooled torch is in use AUT When the unit is switched on the cooler is switched on for 16 s During welding procedures the cooler runs constantly When...

Page 12: ...ooler for 15 seconds to fill the torch cooling circuit 9 ALARMS MANAGEMENT This LED illuminates if an incorrect operating condition occurs An alarm message appears on the following display D1 S1 Press the button to display the additional alarm message Tab 2 Alarm messages MESSAGE ADDITIONAL MESSAGE MEANING EVENT CHECKS Al H t1 xxx t2 xxx xxx temperature measured by the probe Overheating alarm Indi...

Page 13: ...nce signal persists Check that the connection to the cooler is correct Check that the O I switch is set to I and that it illuminates when the pump is running Check that the cooler is filled with coolant Check that the cooling circuit is liquid tight notably the torch hoses and the internal connections of the cooler 10 DERATING Derating is a machine function that cannot be selected by the user Dera...

Page 14: ...parameter allows a shielded environment to be created thereby eliminating contaminants at the start of the welding pass Starting current Unit current output value immediately after the arc strike Up slope time Time during which the current changes from the starting value to the welding value by means of a slope Welding current TIG Current output value during TIG welding Maximum pedal current in TI...

Page 15: ...his parameter enables the unit to receive the current reference signal from a remote control Spot welding time When the torch trigger is pressed the welding arc persists for the time set in the parameter Press the torch trigger again to resume the welding process The arc strike procedure is as follows Positioning of the torch with the electrode on the workpiece Press the torch trigger and keep it ...

Page 16: ...ODE PROCEDURE PARAMETER 1 WELDING CURRENT MMA 1 1 MAXIMUM RC CURRENT IN MMA MODE 2 1 HOT START 1 ARC FORCE 1 PRE GAS TIME 3 3 3 3 3 3 3 3 3 3 3 3 1 STARTING CURRENT 4 4 4 4 4 4 4 4 4 4 4 4 1 UP SLOPE TIME 4 4 4 4 4 4 4 4 4 4 4 4 1 WELDING CURRENT TIG 1 1 1 1 1 1 1 1 1 1 1 1 1 MAXIMUM PEDAL CURRENT IN TIG 2 2 2 2 2 2 1 SECOND WELDING CURRENT 1 BASE CURRENT 1 PEAK TIME 1 BASE TIME 5 5 5 5 5 5 5 5 1 ...

Page 17: ...arameter is set automatically by the microprocessor on the basis of the preset welding current value This value can be displayed but it is not user adjustable When SYN is installed to display the synergic value press the following button S1 12 1 2 MMA PARAMETERS SETTING 2ND LEVEL S3 Hold down the button for 3 seconds to gain access to the 2nd level menu The LED illuminates E1 Use the encoder to sc...

Page 18: ...uit the menu Tab 6 1st level menu parameters in continuous TIG mode PARAMETER MIN DEFAULT MAX P PRE GAS TIME 0 0 s 0 1 s 9 9 s L16 STARTING CURRENT 2 50 200 2 5 A 40 A 200 A 2 L17 UP SLOPE TIME 0 0 s 0 0 s 25 0 s L18 WELDING CURRENT 5 A 80 A 200 A MAX WELDING CURRENT 5 A 80 A 200 A L19 SECOND WELDING CURRENT 10 50 200 1 L20 BASE CURRENT 1 40 200 1 5 SYn SYn SYn 6 L21 PEAK TIME 0 1 s 0 1 s 5 s 5 1 ...

Page 19: ... be set with the foot pedal controller The up slope and down slope cannot be controlled via the foot pedal The following welding procedures can be selected with the foot pedal 2T LIFT ARC 2T HF 2T SPOT 2T SPOT HF If both remote controllers are connected the foot pedal assumes priority over the UP DOWN or potentiometer TIG torch When this function is active welding is performed without the followin...

Page 20: ... S4 Press the button This action will automatically close the menu 13 2 LOADING A USER JOB OF FACTORY SET JOB This function is available when welding mode is not active S4 Press and release the button L xx Only when the jobs have been uploaded the message is shown on the following displays D1 xx number of the latest job used nO J If there are no jobs in the memory the message is shown on the follo...

Page 21: ...Press 1T and keep the torch trigger pressed The arc strikes without contact with the workpiece and the voltage discharges HF cease automatically The welding current reaches the preset value by way of a up slope time if programmed 3 Release 2T the trigger to start the weld completion procedure The current reaches the end current value in the time set in the down slope time parameter The arc is exti...

Page 22: ...t parameter In these conditions the weld pool can be closed crater filler current 6 Release 4T the trigger to extinguish the arc Gas delivery continues for the time set in the post gas parameter 14 6 BI LEVEL HF WELDING 1 Bring the torch up to the work until the electrode tip is approximately 2 or 3 mm away 2 Press 1T and release 2T the torch trigger The arc strikes without contact with the workpi...

Page 23: ...t current for the time set with the spot time parameter The current reaches the end current value in the time set in the down slope time parameter The arc is extinguished Gas delivery continues for the time set in the post gas parameter Touch the workpiece with the torch electrode Slowly lift the torch to strike the arc 14 9 PILOT ARC WELDING The pilot arc can be activated in the following torch t...

Page 24: ...TIG MMA TIG Static characteristic Work cycle 35 60 100 30 60 100 50 60 100 100 Welding current 180 A 130 A 120 A 200 A 140 A 130 A 115 A 110 A 105 A 115 A Working voltage 27 2 V 25 2 V 24 8 V 18 0 V 15 6 V 15 2 V 24 6 V 24 4 V 24 2 V 14 6 V Maximum input power 5 8 KVA 4 0 KVA 3 6 KVA 4 6 KVA 2 9 KVA 2 6 KVA 3 5 KVA 3 3 KVA 3 1 KVA 2 2 KVA Maximum input power 5 6 KW 3 8 KW 3 4 KW 4 3 KW 2 6 KW 2 4 ...

Page 25: ...204T Cod 006 0001 1439 13 05 2013 v2 4 ENGLISH 0 25 31 16 MASTERWELD SPARE PARTS ...

Page 26: ... 0003 0052 TUNNEL HOUSING 25 011 0003 0053 FANS SUPPORT 26 003 0002 0017 FAN 27 010 0006 0042 COMPLETE REAR PLASTIC PANEL 28 013 0003 1300 REAR PANEL 29 022 0002 0206 LED WIRING 30 040 0001 0004 BI POLE SWITCH 31 016 0011 0002 CAP Ø 13 32 045 0000 0014 CABLE CLAMP 33 022 0002 0005 REMOTE CONTROL WIRING 34 033 0005 0013 IMS MODULE 35 043 0002 7014 INLET TOROIDAL FILTER 36 045 0002 0007 NEOPRENE SUP...

Page 27: ...204T Cod 006 0001 1439 13 05 2013 v2 4 ENGLISH 0 27 31 17 ELECTRICAL DIAGRAM 17 1 204T ...

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Page 29: ... 2 TORCH CONNECTOR cod 021 0004 3360 Torch Up Down Torch 17 3 REMOTE CONTROLLER CONNECTOR cod 021 0004 0602 Torch with potentiometer 2 kOhm 10 kOhm potentiometer Remote Controller 2 kOhm 10 kOhm potentiometer Foot pedal controller 2 kOhm 10 kOhm potentiometer ...

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