ESAB TA34 AC/DC Instruction manual

US

Caddy™

TA34 AC/DC

Instruction manual

Valid from program version 1.020460 227 087 US 100315

1 INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Control panel 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 GTAW WELDING 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Settings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Symbol and Function explanations 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Hidden GTAW functions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 SMAW WELDING 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Settings 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Symbol and Function explanations 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Hidden SMAW functions 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 WELDING DATA MEMORY 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 FAULT CODES 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 List of fault codes 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Fault code descriptions 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 ORDERING SPARE PARTS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDERING NUMBER 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rights reserved to alter specifications without notice.

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1 INTRODUCTION

The manual describes the use of TA34 AC/DC control panel.

For general information about operation see instruction manual for the power source.

When mains power is supplied the unit runs a self diagnosis of the LEDs and the display, the program version is displayed and in this example the program version is 0.18.

Instruction manuals in other languages can be downloaded from the website, www.esab.com.

1.1 Control panel

Knob for setting data (current, voltage, percentage, seconds, or frequency)

Display

Choice of welding method GTAW or SMAW

Pushbutton for selection of GTAW-welding with:

S Alternating current AC

S Direct current DC -

S Direct current DC - with pulsing

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Pushbutton for selection of SMAW-welding with:

S Alternating current AC

S Direct current DC -

S Direct current DC +

Choice of HF start or LiftArct

Choice of 2-stroke or 4-stroke

Setting from panel , program change with torch trigger switch or

connecting remote control unit

Display of VRD function (reduced open-circuit voltage) is active or inactive.

(NOTE! This function works for power sources where it is implemented.)

Indication of which parameter is shown in the display (current, voltage,

percentage, seconds or frequency)

Choice of current indication (A) or voltage indication (V) during welding, in the

display

Indication of selected setting parameter, see page 6. The right-hand button is

also used for hidden functions

Buttons for weld data memory settings. See page 13.

2 GTAW WELDING

2.1 Settings

GTAW without pulsing AC/DC and GTAW with pulsing DC

Function Setting range In steps of: Default value

HF / LiftArc t

2/4-stroke

Gas pre flow time

Slope up-time 0 - 10 s 0.1 s 0.0 s

Slope down time 0 - 10 s 0.1 s 1.0 s

Gas post flow time 0 - 25 s 0.1 s 10.0 s

Current 4 - 220 A 1 A 60 A

Active panel OFF or ON - ON

Changing trigger data OFF or ON - OFF

Remote control unit OFF or ON - OFF

Min current

2)

1)

2)

HF or LiftArct - LiftArct

2 stroke or 4 stroke - 2 stroke

0 - 5 s 0.1 s 0.5 s

0-99% - 30%

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GTAW with AC

Function Setting range In steps of: Default value

Balance setting 50 - 98 %* 1 % 50 %

Frequency setting 10 - 152 Hz 1 - 3 Hz 65 Hz

Electrode preheating 0 - 100 1 -

*) Depending on frequency setting.

GTAW with pulsing DC

Function Setting range In steps of: Default value

Pulse current 4 - 220 A 1 A 60 A

Pulse time

Micro pulse

Background current 4 - 220 A 1 A 20 A

Background time

Micro pulse

1)

These functions are hiddenGTAW functions, see description point 2.3.

2)

These functions cannot be changed while welding is in progress

1)

0.01 - 2.5 s

0.001 - 0.250 s

0.01 - 2.5 s

0.001 - 0.250 s

0.01 s

0.001 s

0.01 s

0,001 s

1.0 s

2.2 Symbol and Function explanations

VRD (Voltage Reducing Device)

The VRD function ensures that the open-circuit voltage does not exceed 35 V when welding is not being carried out. This is indicated by a lit VRD LED.

The VRD function is blocked when the system senses that welding has started.

If the VRD function is activated and the open-circuit voltage exceeds the 35 V limit, this is indicated by an error message (16) appearing in the display and welding cannot be started whilst the error message is displayed.

GTAW welding

GTAW welding melts the metal of the workpiece, using an arc struck from a tungsten electrode, which does not melt itself. The weld pool and the electrode are protected by shielding gas.

Alternating current

The advantages of alternating current are reduced risk of magnetic arc blow and good oxide break-up capacity when welding aluminium.

Direct current

A higher current produces a wider weld pool, with better penetration into the workpiece.

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Pulsed current (only DC)

Pulsing is used for improved control of the weld pool and the solidification process. The pulse frequency is set so slow that the weld pool has time to solidify at least partially between each pulse. In order to set pulsing, four parameters are required: pulse current, pulse time, background current and background time.

Parameter settings

1. Slope up

2. Welding current

3. Pulse time

4. Background current

5. Background time

6. Slope down

7. Gas post flow time

8. Balance

9. Frequency

10. Electrode preheating

Slope up

The slope up function means that, when the GTAW arc strikes, the current rises slowly to the set value. This provides `gentler' heating of the electrode, and gives the welder a chance to position the electrode properly before the set welding current is reached.

Pulse current

The higher of the two current values in the event of pulsed current.

Current

Background ti

me

Pulse current

Background cur rent

GTAW welding with pulsing.

Pulse time

Time

Pulse time

The time the pulse current is on during a pulse period.

Background current

The lower of the two current values in the event of pulsed current.

Background time

Time for background current which, along with the time for pulse current, gives the pulse period.

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Slope down

GTAW welding uses “slope down”, by which the current falls 'slowly' over a controlled time, to avoid craters and/or cracks. when a weld is finished.

Gas post-flow

This controls the time during which shielding gas flows after the arc is extinguished.

Balance

Setting the balance between the positive (+) electrode and negative (-) electrode half period during alternating current welding (AC).

Lower balance value produces more heat on the electrode and better oxide break-up on the workpiece.

Higher balance value produces more heat to the workpiece and better penetration.

Frequency

Lower frequency (alternating current) transfers more heat to the workpiece and produces a wider weld pool.

Higher frequency produces a narrower arc with higher arc force (narrower weld pool).

Electrode preheating

Tungsten electrode

Ø inch Colour Type Ar Ar + 30%He

1/16 Green WP - -

1/16 Green WP 30 35

1/16 Black WL10 20 20

1/16 Black WL10 30 35

3/32 Green WP 45 -

3/32 Green WP 55 60

3/32 Black WL10 40 40

Setting value

Shielding gas

3/32 Black WL10 45 50

.126 Green WP 55 -

.126 Green WP 65 65

.126 Black WL10 60 60

.126 Black WL10 70 70

.157 Green WP 70 75

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Tungsten electrode

.157 Green WP 80 85

.157 Black WL10 65 65

.157 Black WL10 70 75

WP = Pure tungsten electrode WL10 = Lantha alloyed tungsten electrode

Setting value

Shielding gas

HF

The HF function strikes the arc by means of a spark from the electrode to the workpiece as the electrode is brought closer to the workpiece.

LiftArct

The LiftArct function strikes the arc when the electrode is brought into contact with the workpiece and then lifted away from it.

Striking the arc with the LiftArc functiont. Step 1: the electrode is touched on to the workpiece. Step 2: the trigger switch is pressed, and a low current starts to flow. Step 3: the welder lifts the electrode from the workpiece: the arc strikes, and the current rises automatically to the set value.

2 stroke

Gas pre-flow Slope

up

Functions when using 2 stroke control of the welding torch.

Slope down Gas post-flow

In the 2 stroke control mode, pressing the TIG torch trigger switch (1) starts gas pre-flow (if used) and strikes the arc. The current rises to the set value (as controlled by the slope up function, if in operation). Releasing the trigger switch (2) reduces the current (or starts slope down if in operation) and extinguishes the arc. Gas post-flow follows if it is in operation.

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4 stroke

Gas pre-flow Slope

up

Functions when using 4 stroke control of the welding torch.

Slope down Gas post-flow

In the 4 stroke control mode, pressing the trigger switch (1) starts gas pre-flow (if used). At the end of the gas pre-flow time, the current rises to the pilot current (a few ampere), and the arc is struck. Releasing the trigger switch (2) increases the current to the set value (with slope up, if in use). When the trigger switch is pressed in (3) the current returns to the set pilot current (with ”slope down” if in use). When the trigger switch is released again (4) the arc is extinguished and any gas post flow occurs.

Active panel

Settings are made from the control panel.

Changing trigger data

This function permits changing between different welding data memories by a double press on the trigger of the welding gun.

Only applies for GTAW welding.

Remote control unit

Settings are made from the remote control unit.

The remote control unit must be connected to the remote control unit socket on the machine before activation. When the remote control unit is activated the panel is inactive.

2.3 Hidden GTAW functions

There are hidden functions in the control panel.

To access the functions, press for 5 seconds. The display shows a letter and a value. Select function by pressing the right arrow. The knob is used to change the value of the selected function.

Function Settings

A = gas pre-flow 0 - 5 s

b = micro pulse 0 = OFF; 1 = ON

I = min current 0 - 99%

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To leave hiddenfunctions, press for 5 seconds.

Gas pre-flow

This controls the time during which shielding gas flows before the arc is struck.

Micro pulse

In order to select micro pulse, the machine must be in the pulsed current function

. The value for pulse time and background current is normally 0.01 – 2.50 seconds. By using the micro pulse, the time can go down to 0.001 seconds. When the micro pulse function is active, times that are shorter than 0.25 seconds are shown in the display without decimal points.

Min current

Used to set the minimum current for the remote control T1 Foot CAN.

If the max current is 100 A and the min current is to be 50 A, set the concealed function min current to 50%.

If the max current is 100 A and the min current is to be 90 A, set the min current to 90%.

This function also applies when setting background current with pulsed TIG.

3 SMAW WELDING

3.1 Settings

Function Setting range In steps of: Default value

Current 16 - max. A

Hotstart 1) 0 - 99 1 0

Arc force 1) 0 - 99 1 5

Drop welding 1) 0=OFF or 1=ON - OFF

Weld regulator ArcPlust 1) 1=OFF or 0=ON - ON

Active panel OFF or ON - ON

Remote control unit OFF or ON - OFF

Min current

2)

0-99% - 30%

2)

1 A 100 A

1)

These functions are hiddenfunctions, see description point 3.3.

2)

The setting range is dependent on the power source used.

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3.2 Symbol and Function explanations

VRD (Voltage Reducing Device)

The VRD function ensures that the open-circuit voltage does not exceed 35 V when welding is not being carried out. This is indicated by a lit VRD LED.

The VRD function is blocked when the system senses that welding has started.

If the VRD function is activated and the open-circuit voltage exceeds the 35 V limit, this is indicated by an error message (16) appearing in the display and welding cannot be started whilst the error message is displayed.

SMAW welding

SMAW welding may also be referred to as welding with coated electrodes. Striking the arc melts the electrode, and its coating forms protective slag.

During SMAW welding, it is possible to weld with reversed polarity without reconnection of welding cables on the power source.

Select SMAW welding and then press

S AC, for alternating current

S DC (-) for direct current with negative polarity on the electrode

S Non LED is on, for direct current with positive polarity on the electrode

Active panel

Settings are made from the control panel.

Remote control unit

Settings are made from the remote control unit.

The remote control unit must be connected to the remote control unit socket on the machine before activation. When the remote control unit is activated the panel is inactive.

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3.3 Hidden SMAW functions

There are hiddenfunctions in the control panel.

To access the functions, press for 5 seconds. The display shows a letter and a value. Select function by pressing the right arrow. The knob is used to change the value of the selected function.

Function Settings

C = Arc Force 0 - 99

d = drop welding 0 = OFF; 1 = ON

F = regulator type ArcPlust 0 = OFF; 1 = ON

H = Hotstart 0 - 99

I = min current 0 - 99%

To leave hidden functions, press for 5 seconds.

Arc Force

The arc force is important in determining how the current changes in response to a change in the arc length. A lower value gives a calmer arc with less spatter.

Drop welding

Drop welding can be used when welding with stainless electrodes. The function involves alternately striking and extinguishing the arc in order to achieve better control of the supply of heat. The electrode needs only to be raised slightly to extinguish the arc.

Welding regulator ArcPlust

Welding regulator ArcPlust is a new type of control that produces a more intense, more concentrated and calmer arc. It recovers more quickly after a spot short-circuit, which reduces the risk of the electrode becoming stuck. Most welding applications obtain the best results with ArcPlust ON (0).

Hot Start

Hot start increases the weld current for an adjustable time at the start of welding, thus reducing the risk of poor fusion at the beginning of the joint.

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4 WELDING DATA MEMORY

Two different welding data programs can be stored in the control panel memory.

Press button or for 5 seconds to store the welding data in the memory. The welding data is stored when the green indicator lamp starts to flash.

To switch between the different welding data memories press button or

.

The welding data memory has a back-up battery so that the settings remain even if the machine has been switched off.

5 FAULT CODES

The fault code is used to indicate that a fault has occurred in the equipment. It is indicated in the display by an E followed by a fault code number.

A unit number is displayed to indicate which unit has generated the fault.

Fault code numbers and unit numbers are shown alternately.

If several faults have been detected only the code for the last occurring fault is displayed. Press any function button or turn the knob to remove the fault indication from the display.

NOTE! If the remote control is activated, deactivate the remote control by pressing

to remove the fault indication.

5.1 List of fault codes

U 0 = welding data unit U 2 = power source U 5 = AC-unit

U 1 = cooling unit U 4 = remote control unit

Fault code Description U 0 U 1 U 2 U 4 U 5

4 Power supply 5 V x x

6 High temperature x x x

7 High temperature x

8 Supply voltage 24V/15V x x

9 Supply voltage -11V x x

12 Communication error (warning) x x x x

14 Communication error (bus off) x

15 Messages lost x

16 High open-circuit voltage VRD x

19 Memory error x

20 High inductance in the welding circuit x

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Fault code U 5U 4U 2U 1U 0Description

25 Lost contact with AC-unit x

26 Program operating fault x

29 No cooling water flow x x

41 Lost contact with the cooling unit x

5.2 Fault code descriptions

Fault code

E 4

U 0

U 5

E 6

U 1

U 2

U 5

E 7

U 5

E 8

U 1

U 5

Description

5 V power supply low

The power supply voltage is too low.

The current welding process is stopped and starting is prevented.

Action: Turn off the mains power supply to reset the unit. Send for a service technician if the fault persists.

High temperature

The thermal overload cut-out has tripped.

The current welding process is stopped and cannot be restarted until the temperature has fallen.

Action: Check that the cooling air inlets or outlets are not blocked or clogged with dirt. Check the duty cycle being used, to make sure that the equipment is not being overloaded.

High temperature

The thermal overload cut-out has tripped.

The current welding process is stopped and cannot be restarted until the temperature has fallen.

Action: Check that the cooling air inlets or outlets are not blocked or clogged with dirt. Check the duty cycle being used, to make sure that the equipment is not being overloaded.

Faulty 24 V/15 V supply voltage

The supply voltage is too high or too low.

The current welding process is stopped and starting is prevented.

E 9

U 1

U 5

E 12

U 0

U 1

U 4

U 5

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Action: Turn off the mains power supply to reset the unit. Send for a service technician if the fault persists.

Faulty 24 V/15 V supply voltage

The supply voltage is too high or too low.

The current welding process is stopped and starting is prevented.

Action: Turn off the mains power supply to reset the unit. Send for a service technician if the fault persists.

Communication error (warning)

Less serious interference on the CAN bus.

Action: Check that there are no faulty units connected on the CAN bus. Check the cables. Send for a service technician if the fault persists.

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Fault code

E 14

U 0

E 15

U 0

E 16

U 2

E 19

U 0

E 20

U 2

Description

Communication error (bus off)

Serious interference on the CAN bus.

Action: Check that there are no faulty units connected on the CAN bus. Check the cables. Send for a service technician if the fault persists.

Communication problems (lost message)

The system's CAN bus has been overloaded.

Action: Send for a service technician if the fault persists. High open-circuit voltage VRD

Open circuit voltage has been too high.

Action: Turn off the mains power supply to reset the unit. Send for a service technician if the fault persists.

Memory error

Content of existing memory is incorrect. Basic data will be used.

Action: Turn off the mains power supply to reset the unit. Send for a service technician if the fault persists.

High inductance in the welding circuit

The power source cannot produce the desired current because the measured inductance in the welding circuit is too high. The fault indication is reset if the inductance reading receives a sufficiently low value at weld start. Resetting can also be achieved by turning off the power.

E 25

U 0

E 26

U 0

E 29

U 0

U 1

E 41

U 0

Action: Use shorter welding cables and ensure that the cables are not coiled up. Place the

welding cable and connector cable next to each other. If possible, the inductance can be reduced by welding with a shorter arc

Send for a service technician if the fault persists.

Lost contact with AC-unit

The control panel has lost contact with the AC unit.

The current welding process stops.

Action: Send for a service technician if the fault persists.

Program operating fault

Something has prevented the processor from performing its normal tasks in the program.

The program restarts automatically. The current welding process will be stopped. This fault does not disable any functions.

Action: Send for a service technician if the fault persists. No cooling water flow

The flow monitor switch has tripped.

The current welding process is stopped and starting is prevented.

Action: Check the cooling water circuit and the pump.

Lost contact with the cooling unit

The welding data unit has lost contact with the cooling unit. The welding process stops.

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Action: Check the wiring. If the fault persists, send for a service technician.

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6 ORDERING SPARE PARTS

When ordering replacement parts, order by part number and part name, as illustrated on the figure. Always provide the series or serial number on the unit on which the parts will be used. The serial number is stamped on the rating plate.

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TA34 AC/DC

Ordering number

Ordering no. Denomination

0460 250 880 Control panel Caddyt TA34 AC/DC 0460 227 070 Instruction manual SE 0460 227 071 Instruction manual DK 0460 227 072 Instruction manual NO 0460 227 073 Instruction manual FI 0460 227 074 Instruction manual GB 0460 227 075 Instruction manual DE 0460 227 076 Instruction manual FR 0460 227 077 Instruction manual NL 0460 227 078 Instruction manual ES 0460 227 079 Instruction manual IT 0460 227 080 Instruction manual PT 0460 227 081 Instruction manual GR 0460 227 082 Instruction manual PL 0460 227 083 Instruction manual HU 0460 227 084 Instruction manual CZ 0460 227 085 Instruction manual SK 0460 227 086 Instruction manual RU 0460 227 087 Instruction manual US 0460 227 089 Instruction manual EE 0460 227 090 Instruction manual LV 0460 227 091 Instruction manual SL 0460 227 092 Instruction manual LT 0460 227 093 Instruction manual CN

Instruction manuals and the spare parts list are available on the Internet at www.esab.com

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NOTES

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NOTES

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ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A CUSTOMER SERVICE QUESTIONS:

Telephone: (800) 362-7080 / Fax: (800) 634-7548 Hours: 8.00 AM to 7:00 PM EST

Order Entry Product Availability Pricing Order Information Returns

B ENGINEERING SERVICE:

Telephone: (834) 664-4416 / Fax: (800) 446-5693 Hours: 7.30 AM to 5:00 PM EST

Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C TECHNICAL SERVICE:

Telephone: (800) ESAB-123 / Fax: (843) 664-4452 Hours: 8.00 AM to 5:00 PM EST

Part Numbers Technical Applications Specifications Equipment Recommendations

D LITERATURE REQUESTS:

Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7.30 AM to 4:00 PM EST

E WELDING EQUIPMENT REPAIRS:

Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7.30 AM to 3:30 PM EST

Repair Estimates Repair Status

F WELDING EQUIPMENT TRAINING:

Telephone: (843) 664-4428 / Fax: (843) 679-5864 Hours: 7.30 AM to 4:00 PM EST

Training School Information and Registrations

G WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 Hours: 7.30 AM to 4:00 PM EST

H TECHNICAL ASST. CONSUMABLES:

Telephone: (800) 933-7070 Hours: 7.30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: (843) 664-4452

Hours: 7:30 AM to 5:00 PM EST

100315

or

visit us on the web at http://www.esabna.com

The ESAB web site offers:

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support

ESAB Welding & Cutting Products

PO BOX 100545, Florence SC 29501-0545

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ESAB TA34 AC/DC Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual