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Linde AG, Linde Gas Deutschland © Ryval 181-221 aXe Manual EN 03
MIG/MAG WELDING MACHINES
Ryval 181 BASIC aXe
Ryval 221 BASIC aXe
INSTRUCTION MANUAL
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Content:
1. INTRODUCTION ............................................................................................. 3
2. SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 3
3. CONDITIONS OF USE ...................................................................................... 7
4. TECHNICAL DATA ........................................................................................... 8
5. ACCESSORIES ................................................................................................. 8
6. DESCRIPTION OF THE APPLIANCE .................................................................. 9
7. GETTING STARTED ....................................................................................... 11
8. WELDING ..................................................................................................... 14
9. ROUTINE MAINTENANCE & INSPECTION ...................................................... 19
10. STATEMENT OF WARRANTY ........................................................................ 20
11. DISPOSAL ..................................................................................................... 21
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1. INTRODUCTION
Congratulations on your new Linde AG, Linde Gas Deutschland product. We
are proud to have you as our customer and will strive to provide you with the
best service and reliability in the industry.
This Operating Manual has been designed to instruct you on the correct use
and operation of your Linde AG, Linde Gas Deutschland product. Your
satisfaction with this product and its safe operation is our ultimate concern.
Therefore please take the time to read the entire manual, especially the
Safety Precautions. They will help you to avoid potential hazards that may
exist when working with this product.
Read and understand this entire Manual and your employer’s safety
practices before installing, operating, or servicing the equipment. While the
information contained in this Manual represents the Manufacturer's best
judgement, the Manufacturer assumes no liability for its use.
Ryval 181 and Ryval 221 BASIC aXe are three phase sturdy welding
machines for MIG/MAG welding.
The machines are designed to produce maximum power output combined
with high reliability and efficiency.
2. SAFETY INSTRUCTIONS AND WARNINGS
1. OPERATION AND MAINTENANCE OF WELDING EQUIPMENT CAN BE
DANGEROUS AND HAZARDOUS TO YOURHEALTH.
2. Arc welding produces intense electric and magnetic emissions that may
interfere with the proper function of cardiac pacemakers, hearing aids, or
other electronic health equipment. Persons who work near arc welding
applications should consult their medical health professional and the
manufacturer of the health equipment to determine whether a hazard
exists.
3. Once the packing has been opened, make sure that the machine is not
damaged. If in any doubt, call the service centre.
4. This equipment must only be used by qualified personnel.
5. During installation, any electric work must only be carried out by trained
personnel.
6. The machine must be used in a dry place with good ventilation.
7. Make sure that no metal dust can be drawn in by the fan inside the
machine, as this could cause damage to the electronic circuits.
8. It is prohibited to connect more than one generator in series or in parallel.
9. When installing the machine, follow the local regulations on safety.
10. The position of the machine must allow easy access by the operator to
the controls and connectors.
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11. When the welding machine is operating, all its covers and doors must
be closed and well fixed.
12. Do not expose the welding machine to direct sunlight or to heavy rain.
This equipment conforms to protection rating IP23S.
13. The operator must wear gloves, clothes, shoes, and a helmet or a
welder’s helmet, which protect and are fire-resistant in order to protect
him against electric shock, flashes and sparks from cutting.
14. The operator must protect his eyes with safety visor or mask designed
for welding, fitted with standard safety filters. He should also be aware
that during arc welding ULTRAVIOLET RADIATION is emitted. Therefore
it is vital that his face is also protected from radiation. Ultraviolet rays
produce the same harmful effect as sun burning on unprotected skin.
15. The operator is obliged to warn anyone near the welding area of the
risks that welding involves and to arrange to provide adequate protection
equipment.
16. Keep all fumes and gases from the breathing area.
17. Keep your head out of the fume plume.
18. Use an air-supplied respirator if ventilation is not adequate to remove
all fumes and gases.
19. The kinds of fumes and gases from the plasma arc depend on the kind
of metal being used, coatings on the metal, and the different processes.
You must be very careful when welding any metals which may contain
one or more of the following:
Antimony Chromium Mercury
Nickel Cobalt Arsenic
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
20. Always read the Material Safety Data Sheets (MSDS) that should be
supplied with the material you are using. These MSDSs will give you the
information regarding the kind and amount of fumes and gases that may
be dangerous to your health.
21. It is very important to arrange for sufficient ventilation, especially when
welding in enclosed spaces. We suggest using suitable fume extractors to
prevent the risk of intoxication by fumes or gas generated by the welding
process.
22. Noise can cause permanent hearing loss. Welding arc processes can
cause noise levels to exceed safe limits. You must protect your ears from
loud noise to prevent permanent loss of hearing.
23. To protect your hearing from loud noise, wear protective ear plugs
and/or ear muffs. Protect others in the workplace.
24. Noise levels should be measured to be sure the decibels (sound) do
not exceed safe levels.
25. The operator must ensure all flammable materials are removed from
the work area to avoid any risk of fire.
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26. The operator must NEVER weld containers that have previously
contained petrol, lubricants, gas or similar flammable materials, even if
the container has been empty for a considerable time. THERE IS A VERY
HIGH RISK OF EXPLOSION.
27. The operator must be aware of all the special regulations which he
needs to conform to when cutting in enclosed spaces with a high risk of
explosion.
28. To prevent electric shock, we strongly suggest the following rules:
29. Do not work in a damp or humid environment.
30. Do not use the machine if its cables are damaged in any way.
31. Make sure that the earthing system of the electric equipment is
correctly connected and operational.
32. The operator must be insulated from the metal components connected
to the return wire.
33. The earthing of the piece being worked could increase the risk of injury
to the operator.
34. EN 60974-1 Standard: Open-circuit voltage. During the operation of
the machine, the highest voltage, with which it is possible to come into
contact, is the open-circuit voltage between the clamps.
35. The maximum open-circuit voltage of the plasma machines is
established by national and international standards (EN 60974-1)
depending on the type of current to be used, on its waveform and on the
hazards arising from the work place. These values are not applicable to
the strike currents and those for stabilisation of the arc that could be
above it.
36. The open-circuit voltage, for as many adjustments as possible, must
never exceed the values relating to the various cases shown in the
following table:
Case Working conditions Open-circuit voltage
1 Places with increased
risk of electric shock
DC current: 113V
peak value
AC current: 68V
peak value and 48V
effective
2 Places without increased
risk of electric shock
DC current: 113V
peak value
AC current: 113V
peak value and 80V
effective
3 Torches held
mechanically with
increased protection for
the operator
DC current: 141V
peak value
AC current: 141V
peak value and
100V effective
4 Plasma cutting DC current: 500V
peak value
37. In case 1, the dc machines with rectifier must be built in such a way
that, in case of a fault developing in the rectifier (for example open circuit,
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short circuit or lack of power), the permitted values cannot be exceeded.
The welding machines of this type can be marked with the symbol:
S
38. Before opening the machine switch off the machine and disconnect it
from the power socket.
39. Only personnel authorised by this company can carry out maintenance
on the machine.
PROTECTIVE UTTILITIES
1. Welding helmet with filter shade at least 10
2. Welding gloves
3. Welding apron and cloth
4. Welding boots
RISK OVERVIEW
1. Risk of electric shock.
2. Ultraviolet light and light radiation
3. Risk of inhaling gas fumes and dust particles
4. Burns
5. Noise
NOTE
1. It is forbidden to operate a machine with damaged insulation of the
welding torch or supply cable.
2. Never operate the machine taken down or damaged covers.
3. It is forbidden to operate the machine in wet environments and outdoors
in rain or snow.
4. Ensure proper grounding clamping pliers, which also reduces the risk of
electric shock.
5. Use prescribed protective utilities, keep them dry.
6. Arc welding produces intense electric and magnetic emissions that may
interfere with the proper function of cardiac pacemakers, hearing aids,
or other electronic health equipment. Persons who work near plasma
arc cutting applications should consult their medical health professional
and the manufacturer of the health equipment to determine whether a
hazard exists.
7. Never aim the torch against the eyes, body or other person.
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3. CONDITIONS OF USE
1. This equipment must only be used by qualified personnel.
2. During installation, any electric work must only be carried out by trained
personnel.
3. Device complies with IEC 61000-3-12.
4. Do not expose the plasma machine to direct sunlight or to rain or snow.
This equipment conforms to protection rating IP23S.
5. Place the machine the way that the cooling air can enter the vents without
restriction to. It is necessary to ensure that no impurities, especially metal
particles are not drawn into the machine.
6. Welding machine in terms of interference suppression is intended
primarily for industrial premises. In the case of use of other areas may be
need for special measures (see EN 60974-10).
7. The machine must be protected against
a) Moisture and rain and snow
b) Mechanical damage
c) Draft and any ventilation of neighbouring machine
d) Excessive overloading - crossing technical parameters
e) Rough handling
ELECTROMAGNETIC COMPATIBILITY
The welding device is in terms of interference designed primarily for
industrial areas. It meets the requirements of EN 60974-10 class A and it
isn’t designed for using in residential areas, where the electrical energy is
supplied by public low-voltage power supply network. It can be here potential
problems with ensuring of electromagnetic compatibility in this areas, due to
interference caused by power lines as well as the radiated interference.
During operation, the device may be the source of interference.
Caution
We warn users, that they are responsible for possible interference from
welding.
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4. TECHNICAL DATA
Ryval 181 Ryval 221
Mains voltage V/Hz
3 x 400/50 3 x 400/50
Mains protection A
10 @ 16 @
Max. input power I1 A
8,9 12,1
Max. effective current I1eff A
5,9 7,7
Welding current range A
30 - 180 30 - 210
Open-circuit voltage U20 V
19,3 - 37,7 20,8 - 43,6
Welding current (DC=100%) I2 A
130 150
Welding current (DC=60%) I2 A
150 170
Welding current (DC=x%) I2 A
40%=180 40%=210
Voltage steps
7 7
Insulation class
F F
Protection
IP 23S IP 23S
Standards
EN 60974-1; EN 60974-10 class A
Dimensions (w x l x h) mm
474 x 888 x 561 474 x 888 x 561
Weight kg
61 65
Wire speed m/min
1 - 17 1 - 17
Spool diameter mm
300 300
Spool weight kg
18 18
5. ACCESSORIES
DELIVERED WITH THE MACHINE
1. Earthing cable 3m with a clamp
2. Feed roll 0,6 - 0,8 mm for ALF 181; 0,8 - 1,0 mm for ALF 221
3. Gas hoses
4. Reduction for the wire spool
ACCESSORIES TO ORDER
1. Wire cleaner
2. CO2 Gas pre heating cable
3. Reduction valve KU 5, K 2
4. Gas cylinder
5. Torch consumables
6. Earthing cable 4 - 5 m
7. Feed rolls 0,6-0,8, for carbon steels, aluminium, flux core wires
8. Welding torches
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6. DESCRIPTION OF THE APPLIANCE
MAIN PARTS
Fig. 1 - Main parts
A1 ON / OFF Switch
A2 Voltage switch
A3 LED ON Indicator
A4 Work leads
A5 LED over heating indicator
A6 Wire speed potentiometer
A7 EURO connector
A8 Gas heater connector
A9 Solenoid Valve – gas connector
A10 Mains cable
A11 Chain for fixing the gas cylinder
A12 Wire Feeder
A13 Spool Holder
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CONTROL PANEL - OVERVIEW
Fig. 2 - Control panel
A1 PCB - encoder ON / OFF Switch
A2 Voltage switch
A3 LED ON Indicator
A5 LED over heating indicator
P1 Wire speed potentiometer
P2 Spot time potentiometer
P3 Interval time potentiometer
WIRE FEEDER
Fig 3 – Wire feeder
Pos. Description
E1 Fixing shaft
E2 Pressure arm
E3 Liner- Feeder
E4 EURO connector
E5 Roll, Plastic cup
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a
b
PS 2(W) PS 4(W)
2-rolls 4-rolls
a = 22 mm a = 22 mm
b = 30 mm b = 30 mm
Grove type Wire diameter Item No
Steel
0,6-0,8 2187
0,8-1,0 2188
Aluminium
0,8-1,0 2270
1,0-1,2 2269
1,6-2,0 2513
Flux core
0,8-1,0 2318
1,0-1,2 2319
7. GETTING STARTED
Getting started must be consistent with technical data and conditions of use.
Fig 4 – Earthing cable connecting
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B1 Euro connector female
B2 Torch Euro connector
B3 Welding torch
C1 Work lead
C2 Earthing clamp
1. Connect the earthing clamp C2 to the welding piece.
2. Connect the B1 and B2 torch connectors together. Screw them up
properly by mean turning the B2 clockwise.
3. Plug the mains plug to 3x400 V mains.
4. Switch the machine on by the ON/OFF switch A1.
INSERTING THE WIRE
Fig. 5 – Spool holder
1. Open the side cover of the wire feeder space.
2. Put the wire spool on the wire spool holder D1 using the adapter D3 and
fix it with the fixing nut D2.
3. Cut off the curved or damaged end of welding wire and lead it through the
inlet liner E3, and the roll into the liner inside the EURO torch connector
(about 5 cm). Make sure, that you use the suitable groove.
4. Put the pressure arm E2 down in that way, that the teeth or the gear fit
and fix it by setting the lever E1 into vertical position.
5. Adjust the pressure nut that way that it provides constant movement of
wire but it does not deform wire.
INSERTING THE WELDING WIRE INTO THE WELDING TORCH
1. See the manual of the welding torch.
2. Take off the torch gas cup.
3. Take off the torch tip.
4. Press the torch trigger, the wire will start feeding into the torch.
5. When the wire reaches the end of the torch, release the trigger, screw on
the tip and the nozzle.
CHANGING THE WIRE FEEDER ROLL
1. Every wire feeding roll in Linde AG, Linde Gas Deutschland machines can
be used for two different diameters of welding wire – the rolls have two
grooves.
2. When the machine is equipped with two roll wire feeder move the lever E1
D1 Spool holder
D2 Nut spool holder
D3 Adapter
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to the right (2 roll feeder)/ forward (4 roll feeder). The pressure arm shall
pop up.
3. Unscrew the plastic fixing cup E5 and take off the roll.
4. In case there is suitable groove on the roll, turn it around and fix it back to
the feeder.
∅ 1,0
1,0
1,20,8
A
B
C
Fig. 6- The influence of the roll groove on the wire
ADJUSTING THE MACHINE FOR WELDING OF ALUMINIUM
1. For feeding the AL wire it is necessary to use roll with the “U” profile of the
groove. To prevent problems with feeding use wires with diameter 1,0 or
more mm of AlMg3 or AlMg5. The torch must be equipped with Teflon
liner and special tip. As shielding atmosphere use Argon.
Fig 7 – Set for welding aluminium
G1 EURO connector
G2 Rolls
G3 Liner terminal for 4,0mm, 4,7mm outer diameter
G4 O – ring 3,5x1,5mm
G5 Nut
G6 Teflon Liner
G7 Sustain pipe for teflon and plastic liner
GAS FLOW SETTING
The electric arc and the weld must be perfectly shielded by gas. Too small
amount of gas does not perform the protective atmosphere and on the other
hand to big amount of the gas brings air into the electric arc.
A Correct
B Wrong
C Wrong
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Fig. 8 – Gas fitting
F1 Gas Cylinder
F2 Cylinder Valve
F3 Gas heater connector
F4 Pressure Reducer
F5 High Pressure Manometer
F6 Low Pressure Manometer
F7 Adjusting Screw
F8 Gas outlet
F9 Solenoid Valve
F10 Chain
1. Place the gas cylinder on the platform and fix it properly by the fixing
chain. We recommend using bolts and nuts to fix it more safely.
2. Connect the pressure reduction valve on the gas cylinder.
3. Connect the gas hose to gas outlet F8 on the valve and the gas inlet F9
on the machine.
4. In case you use gas CO2 it may be needed to use suitable gas heater
(only above 6 l/min). Connect the heater to the F3 heater connector
(optional). Use type corresponding to voltage and current given on the
shield.
5. Open the F2 cylinder valve.
6. Press the torch trigger.
7. Adjust the amount of gas on the reduction gas valve (it is not a part of the
welding machine) by the F7 adjusting screw.
8. Release the torch trigger.
8. WELDING
For orientating adjusting of the welding current and voltage you can use
empirical relation U2 = 14+0,05 2. From that you can specify desired voltage.
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SETTING WELDING CURRENT AND VOLTAGE
When the wire had been installed and gas had been set it is possible to start
welding.
The appliance must be plugged into the mains, the ON/OFF switch A1 on "I".
To select the voltage use step switch A2.
To select the current (that is linked to the wire speed) use the potentiometer
A6 (P1).
WELDING MODES
Machines works in four modes:
1. Continuous two stroke (2T)
2. Continuous four stroke (4T)
3. Spot welding
4. Interval welding
TWO STROKE
P2
P3
Both potentiometers P2, P3 are in the OFF position. Welding
procedure starts by pressing the button in the torch handle. It is necessary to
keep the button pressed all the time during welding. The welding stops by
releasing the torch button.
1
2
Welding proces
FOUR STROKE
P2
P3
The four stroke mode is being used mostly for long welds, when
there is no need to hold the torch button pressed. The left potentiometer P2
is in the OFF position, the right potentiometer P3 is in the ON position. The
welding procedure start by pressing the torch button; after releasing the torch
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button the welding continues. The welding stops after the second pressing
and releasing the torch button then.
1- 2
3 - 4
Welding proces
SPOT WELDING
P2
P3
The spot welding mode is being used for welding short welds of
the same length. The length (welding time) can be set by the left
potentiometer P2, the right potentiometer P3 must be in the OFF position.
The pressing the torch button activates the time circuit that starts and end
the welding procedure.
1
2
Welding proces
1
2
Welding proces
INTERVAL WELDING
P2
P3
The interval welding mode is being used for welding repeated
short welds of the same length of welding time and the pause time. The
length of welding time can be set by the left potentiometer P2, the pause by
the right potentiometer P3. By pressing the torch button activate the time
circuit that starts and end the welding procedure.
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1
Welding proces
2
Welding proces
Pause
BURN BACK SETTING
1234568 79101112
t
300ms
max
t
20 ms
min
Burn back time
Fig. 9 – Burn back time trimmer
The burn back function if set suitably prevents sticking the welding wire into
the welding tip. The default time is 50-80 ms. I tis possible to change the
burn back time by means of a trimmer placed on the rear side of the control
board. It is necessary to take off the front panel. Only a qualified person may
curry out this operation.
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TABLE OF WELDING PARAMETERS
Recommended welding parameters - Ryval 181
Wire (EN ISO 14341) G2Si1, G3Si1, G4Si1 - 0,8 mm
Gas (EN ISO 14175) M21 - Ar 82%, CO2 18%
1 2 3 4 5 6 7
A --- 65 95 122 150 165 180
m/Min. --- 2,0 3,0 4,0 5,0 6,0 7,5
mm --- 0,8 1,5 2,0 3,0 4,0 5,0
Wire (EN ISO 14341) G2Si1, G3Si1, G4Si1 - 1,0 mm
Gas (EN ISO 14175) M21 - Ar 82%, CO2 18%
1 2 3 4 5 6 7
A --- 80 130 155 180 200 215
m/Min. --- 1,5 2,3 3,0 3,5 4,0 4,5
mm --- 0,8 1,5 2,0 3,0 4,0 5,0
Wire (EN ISO 14341) G2Si1, G3Si1, G4Si1 - 0,8 mm
Gas (EN ISO 14175) C1 - CO2 100%
1 2 3 4 5 6 7
A --- 50 80 108 125 140 157
m/Min. --- 1,8 2,5 3,5 4,0 5,0 6,0
mm --- 0,8 1,5 2,0 3,0 4,0 5,0
Wire (EN ISO 14341) G2Si1, G3Si1, G4Si1 - 1,0 mm
Gas (EN ISO 14175) C1 - CO2 100%
1 2 3 4 5 6 7
A --- 65 100 130 150 170 180
m/Min. --- 1,2 1,8 2,3 2,8 3,2 3,5
mm --- 1,0 1,5 2,0 3,0 4,0 5,0
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Recommended welding parameters - Ryval 221
Wire (EN ISO 14341) G2Si1, G3Si1, G4Si1 - 0,8 mm
Gas (EN ISO 14175) M21 - Ar 82%, CO2 18%
1 2 3 4 5 6 7
A
45 85 118 160 182 194 227
m/Min.
1,0 2,0 3,0 4,2 5,5 7,0 9,0
mm
0,8 1,5 2,0 3,0 4,0 5,0 6,0
Wire (EN ISO 14341) G2Si1, G3Si1, G4Si1 - 1,0 mm
Gas (EN ISO 14175) M21 - Ar 82%, CO2 18%
1 2 3 4 5 6 7
A
60 100 130 175 200 230 245
m/Min.
1,2 2,0 2,5 3,6 4,3 5,0 5,8
mm
1,0 1,5 2,0 3,0 4,0 5,0 6,0
Wire (EN ISO 14341) G2Si1, G3Si1, G4Si1 - 0,8 mm
Gas (EN ISO 14175) C1 - CO2 100%
1 2 3 4 5 6 7
A
--- 50 90 124 160 178 188
m/Min.
--- 1,2 3,0 4,2 5,5 6,8 8,1
mm
--- 0,8 2,0 3,0 4,0 5,0 6,0
Wire (EN ISO 14341) G2Si1, G3Si1, G4Si1 - 1,0 mm
Gas (EN ISO 14175) C1 - CO2 100%
1 2 3 4 5 6 7
A
--- 78 105 135 155 195 225
m/Min.
--- 1,5 2,0 2,4 3,2 4,0 5,5
mm
--- 1,0 1,5 2,0 3,0 4,0 5,0
9. ROUTINE MAINTENANCE & INSPECTION
1. The only routine maintenance required for the Ryval range of machines is
a thorough cleaning and inspection, with the frequency depending on the
usage and the operating environment.
WARNING
2. Disconnect the Ryval from the mains supply voltage before
disassembling.
3. Special maintenance is not necessary for the control unit parts in the
Welder. If these parts are damaged for any reason, replacement is
recommended.
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CAUTION
4. Do not blow air into the welder during cleaning. Blowing air into the welder
can cause metal particles to interfere with sensitive electronic
components and cause damage to the welder.
5. To clean the welder, disconnect it from the mains supply voltage then
open the enclosure and use a vacuum cleaner to remove any
accumulated dirt and dust. The welder should also be wiped clean. If
necessary, solvents that are recommended for cleaning electrical
apparatus may be used.
6. Troubleshooting and repairing of Ryval welding equipment should only be
carried out only by suitably qualified or competent person.
7. A ‘competent person’ must be a person who has acquired through
training, qualification or experience, or a combination of them, the
knowledge and skills enabling that person to safely carry out a risk
assessment and repairs to the electrical equipment in question.
8. The person carrying out the servicing needs and repairs must know what
to look at, what to look for and what to do.
10. STATEMENT OF WARRANTY
1. In accordance with the warranty periods stated below, Linde AG, Linde
Gas Deutschland guarantees the proposed product to be free from
defects in material or workmanship when operated in accordance with the
written instructions as defined in this operating manual.
2. Linde AG, Linde Gas Deutschland welding products are manufactured for
use by commercial and industrial users and trained personnel with
experience in the use and maintenance of electrical welding and cutting
equipment.
3. Linde AG, Linde Gas Deutschland will repair or replace, at its discretion,
any warranted parts or components that fail due to defects in material or
workmanship within the warranty period. The warranty period begins on
the date of sale to the end user.
4. If warranty is being sought, please contact your Linde AG, Linde Gas
Deutschland product supplier for the warranty repair procedure.
5. Linde AG, Linde Gas Deutschland warranty will not apply to:
6. Equipment that has been modified by any other party other than Linde
AG, Linde Gas Deutschland’s own service personnel or with prior written
consent obtained from Linde AG, Linde Gas Deutschland Service
Department.
7. Equipment that has been used beyond the specifications established in
the operating manual.
8. Installation not in accordance with the installation/operating manual.
9. Any product that has been subjected to abuse, misuse, negligence or
accident.
10. Failure to clean and maintain (including lack of lubrication,
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maintenance and protection), the machine as set forth in the operating,
installation or service manual.
11. Within this operating manual are details regarding the maintenance
necessary to ensure trouble free operation.
NOTE
12. Warranty repairs must be performed by either an Linde AG, Linde Gas
Deutschland Service Centre, an Linde AG, Linde Gas Deutschland
distributor or an Authorised Service Agent approved by the company
Linde AG, Linde Gas Deutschland.
11. DISPOSAL
Only for EU countries. Do not dispose of electric tools together with
household waste material.
In accordance with European Council Directive 2002/96/EC on
electrical and electronic equipment waste and its implementation in
accordance with national law, electric tools that have reached the end of
their service life must be collected separately and returned to an
environmentally compatible recycling facility.
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