Ter Welding Multi Synergic 250, Multi Synergic 380, Multi Synergic 500 Instruction Manual
IT
Italiano
Manuale Istruzione
IT
Multi Synergic 250 - Multi Synergic 380 - Multi Synergic 500 and Accessories
Multi Synergic 250 - Multi Synergic 380 - Multi Synergic 500 and Accessories
This manual must be completed by the “CE Operating and service maual”
Edition of 22/11/2011 Rev.00
GB
English
Instruction Manual
Multi Synergic 250 - Multi Synergic 380 - Multi Synergic 500 and Accessories
GB
English
Instruction Manual
Multi Synergic 250 - Multi Synergic 380 - Multi Synergic 500 and Accessories
GB
English
Instruction Manual
Multi Synergic 250 - Multi Synergic 380 - Multi Synergic 500 and Accessories
DESCRIPTION CHAP. PAGE
1. DECLARATION OF CONFORMITY 01
2. RAEE STANDARDS 02
3. SAFETY PRECAUTIONS 02
4. GENERAL DESCRIPTION 02
5. STAND BY 03
6. VRD - VOLTAGE REDUCTION DEVICE 03
7. ALARMS AND SETTINGS 03
8. POWER SUPPLY QUALITY IN THE VOLTAGE, IN THE MISSING PHASE, 03
IN THE FREQUENCY
9. OUTPUT WELDING CONDITIONS, SHORT CIRCUIT OR 03
WELDING OVER LIMITS
10. AUXILIARY ELECTRONIC WARNING AND FAILURE 04
11. WATER COOLING UNIT STATUS 04
12. COMMUNICATION WITH THE EXTERNAL WIRE FEEDER 04
13. ACCESSORIES 05
14. MAIN FEATURES MULTI SYNERGIC 280 05
15. MAIN FEATURES MULTI SYNERGIC 350 06
16. MAIN FEATURES MULTI SYNERGIC 500 07
17. FRONT PANEL FUNCTIONS AND ADJUSTMENTS 08
18. FRONT PANEL LAYOUT 09
19. MANUAL ELECTRODE SETTING. CONNECT THE WORK PIECE CABLE TO 10
THE NEGATIVE RECEPTACLE, AND THE ELECTRODE OLDER T THE POSITIVE
RECEPTACLE
20. TIG SETTING. CONNECT THE GAS INPUT TO THE GAS REGULATOR AND A 11
DJUST THE GAS FLOW BETWEEN 6 TO 8 LITRES PER MINUTE
21. MANUAL PULS TIG SET 12
DESCRIPTION CHAP. PAGE
22. SYNERGIC TIG SETTING 13
23. MIG-MAG WELDING 14
24. MIG-MAG MANUAL 15
25. MIG-MAG SYNERGIC 16
26. PULS MIG SYNERGIC 17
27. DIGITAL TORCH 19
INDEX
GB
English
Instruction Manual
Multi Synergic 250 - Multi Synergic 380 - Multi Synergic 500 and Accessories
WARNING
IMPORTANT: BEFORE STARTING THE EQUIPMENT, READ THE CONTENTS OF THIS MANUAL, WHICH MUST BE STORED IN A PLACE FAMILIAR TO ALL
USERS FOR THE ENTIRE OPERATIVE LIFE-SPAN OF THE MACHINE.THIS EQUIPMENT MUST BE USED SOLELY FOR CUTTING OPERATIONS.
INTRODUCTION
To obtain the best performance from the machine and ensure the longest possible life of all its components you must careffully follow the instructions for use and
maintenance detailed in this manual. In the interest of our customers we suggest any maintenance or repair of the equipment is made by qualied personnel.
All our products are subject to a constant development. We are therefore constrained to reserve the right to make any necessary or useful changes in design and
equipment.
ROUTINE MAINTENANCE
Prevent metal powder from accumulating inside the equipment. Disconnect the power supply before every operation ! Carr y out the following periodic controls on
the power source:
• Clean the power source inside by means of low-pressure
compressed air and soft bristel brushes.
• Check the electric connections and all the connection cables.
For the use and maintenance of the pressure reducers, consult the specic manuals.
GB
English
Instruction Manual
Multi Synergic 250 - Multi Synergic 380 - Multi Synergic 500 and Accessories
1. DECLARATION OF CONFORMITY
TER SRL - Via Leopardi, 13 - 36030 Caldogno (VI) Italy
Declares that generators described in this manual, in particular the:
Multi Synergic 280
Multi Synergic 350
Multi Synergic 500
and accessories:
wire feeder unit
DRC remote control unit
DRC remote control unit for automation
Multi Synergic cooling unit with cable assembly and torches
has been designed in compliance with the following standards:
– EN 60974-12 - EN 60974-1 - EN 60974-10
– EN 60974-2 - EN 60974-5
Maurizio Terzo
Direttor Generale
Date 22/02/2010
IN CASE OF ANY TECHNICAL PROBLEM ASK FOR QUALIFIED SERVICE ASSISTANCE
Page. 01
GB
English
Instruction Manual
Multi Synergic 250 - Multi Synergic 380 - Multi Synergic 500 and Accessories
2. RAEE STANDARDS
The symbol on the product or on its packaging indicates that this product
may not be treated as household waste. Instead it shall be handed over to
the applicable collection point for the recycling of electrical and electronic
equipment. By ensuring this product is disposed of correctly, you will help
prevent potential negative consequences for the environment and human health,
which could otherwise be caused by inappropiate waste handling of this product.
For more detailed information about recycling of this product, please contact your
local city ofce, your household waste disposal service or the shop where you
purchased the product.
3. SAFETY PRECAUTIONS
WELDING AND ARC CUTTING CAN BE HARMFUL TO YOURSELF AND OTHERS.
The user must therefore be educated against the hazards, summarized below, deriving from welding operations.
RISK of FIRE and BURNS
Sparks (sprays) may cause res and burn the skin; you should therefore
make sure there are no ammable materials in the area, and wear appro-
priate protective garments.
NOISE
This machine does not directly produce noise exceeding 80dB. The plas-
ma cutting/welding procedure may produce noise levels beyond said limit;
users must therefore implement all precautions required by law.
PACE MAKER
The magnetic elds created by high currents may af fect the operation of
pacemakers. Wearers 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.
ELECTRIC SHOCK – May be fatal
Install and earth the welding machine according to the applicable regulations. Do not touch live electrical parts or eletrodes with bare skin,
gloves or wet clothing.Isolate yourselves from both the earth and the
workpiece. Make sure your working position is safe.
FUME and GASES – May be hazardous to your health
Keep your head away from fumes. Work in the presence of adequate ventilation, and use ventilators around the arc to prevent gases from forming
in the work area.
ARC RAYS – May injure the eyes and burn the skin
Protect yuor eyes with welding masks tted with ltered lenses, and
protect your body with appropiate safety garments.
Protect others by installing adequate shields or curtains.
4. GENERAL DESCRIPTION
This machine is a constant direct current power source, designed for welding
electrically conductive materials (metals and alloys) using the electical arc
procedure.
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GB
English
Instruction Manual
Multi Synergic 250 - Multi Synergic 380 - Multi Synergic 500 and Accessories
5. STAND BY
The machine stops its main functions when it is not continuosly used,
in order to reduce the power consumption at 10W; the “STANDBY” icon
lights. The fan works only when the machine needs to be cooled down;
during light applications, the fan normally doesn’t work.
The water cooling unit, if any, wo rks only on MIG proce ss; at the end of th e mi g we lding process, it works for further 180 sec.
6. VRD - VOLTAGE REDUCTION DEVICE
This feature reduces the output no load voltage <25V.
It increases the safety conditions of the operator: the no load voltage is not dan-gerous but any contact between human body and
live parts may cause a shock with lost of equilibrium control or
similar.
The VRD feature is activated with “VRD” light on. The feature is always “on”:
the system grants efcient arc stricking even with a no load voltage <15V.
On manual MIG process it becomes automatically “off”.
To set the VRD on On or Off, push the pushbutton for ten seconds up to the icon
VRD light on or the icon V>2 0 light on
7. ALARMS AND SETTINGS
The power sources Multi synergic are completed with a monitoring system of the
machine conditions in order to avoid failure in the machine and in the welding.
In particular the alarms involve in:
Power supply quality in the voltage, in the missing phase, in the frequency.
Output welding conditions, short circuit or welding over limits Inverter over heating
or over load or over current.
Auxiliary electronic warning and failure wire feeder status water cooling unit status
communication with the external wire feeder.
REFER TO THE TROUBLESHOOTING, PARAGRAPH FOR THE DETAILS
- 24 -
8. POWER SUPPLY QUALITY IN THE VOLTAGE, IN THE MISSING
PHASE, IN THE FREQUENCY:
The tri-phase welding generators have an input voltage of 400V ( min 340V – max
480V). MULTI SYNERGIC versions can be supplied with motor generators and/or
long cables (within the min/max input voltage limits).
In case current exceeds the mentioned limits (current peaks), machine functions
stop and display shows the detected current peak.
Reset the machine by switching the main ON/OFF knob.
The tri-phase version detects even the right presence of the three current phases
and, should one of those fail for > 20 m/s, machine functions stop and display
will show the missing phase. Again, reset the machine by switching the main ON/
OFF knob.
In the case of shift of supply net frequency the machine is stopped an the appropriate alarm is shown in the display (this case can occurs when the supply is
coming from motor generator and the the frequency goes outside the limits of
50-60 Hz.
9. OUTPUT WELDING CONDITIONS, SHORT CIRCUIT OR
WELDING OVER LIMITS
A circuit test is released every time you switch “ON” the machine. The correct
output polarities are checked-out and in case of an eventual shor t circuit detection, machine enters in alarm standby showing on the display:
Once short circuit conditions are removed, machine test will continue correctly.
Short circuit conditions may appear even during the welding job: in case they
persist continuously for more than 5 sec, generator enter in “short circuit alarm”.
The “anti sticking” icon lights too.
Fires, burns and shocks may be caused by uncorrected current outputs.
Reasons may be found on:
• involuntary failures on mig jobs which may release, without any control, the
weld ing wire: it melt entering in contact with negative polarities generating possible fire and burn conditions
• damaged cables, with insulation losses, etc.
In case of any output failure, the machine enters in alarm condition showing: ALL
OUT
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English
Instruction Manual
Multi Synergic 250 - Multi Synergic 380 - Multi Synergic 500 and Accessories
The MULTI series generators are characterised by a its ED factor – 40% at 40°C and
power supply may, in cer tain cases, be sufcient for this output but the used can
adjust higher power output causing damages on the existing supply network. (or can
use long interconnecting cable at maximum output current).
The MULTI SYNERGIC series controls regularly the output power Vs the input power
value and in case of any discrepancy the welding stops and the display will shows:
ALL Ed xxx: The machine will be available again at the end of the count-down
shown on the display.
INVERTER OVER HEATING OR OVER LOAD OR OVER CURRENT
The MULTI SYNERGIC series generators are fan cooled. Forced ventilation is activated
once the inverter temperature exceed the 40°C and fan turns automatically off once internal components are correctly cooled.
Fan cooling is anyway rarely activated: it may occurs when duty cycle has been exceeded, in case of high environment temperatures, etc.
In case of overheating, output is disabled and display will shows:
ALL OL
10. AUXILIARY ELECTRONIC WARNING AND FAILURE
The Internal electronic is governed by software and when errors come from the execution
of the cycles the display shows the alarms that can be ALL MEM, ALL TAB, I2C OCC,
when those alarms occurs may be the machine still works, refer to the troubleshooting
for the solution.
WIRE FEEDER STATUS
The wire feeder is digitally controlled, and ever, the wire speed has the right value,
in the case that something doesn’t works properly two alarms indicates the kind of
failure :
ALL ENC and ALL BRA that means a wrong or missing speed or a wrong or
missing brake status of the motor at the end of the welding, refer to the troubleshooting for the solution.
11. WATER COOLING UNIT STATUS
When the generator is equipped with the cooling unit, the correct cooling liquid circulation is constantly controlled. The cooling unit works only when Mig,
Pulsed Mig or Tig processes are activated.
The cooling unit pump is activated switching the torch trigger and turns off after
some time that the welding job end.
In case of liquid circulation failures, output is disabled and display will show:
ALL h2o
Reset the machine switching the main knob ON/OFF.
Long inactivity periods may damage the cooling unit pump or generate momentary re-start problems. First ensure the presence of liquid inside the tank and
control the right positioning of the in/out hoses – following instructions may help:
• unplug the water-out blu hose from the machine rear panel and plug a temporary hose
• push & release the torch trigger once: cooling unit pump test should be activated for 15 seconds
• cooling liquid should flow from the temporary hose: if not, repeat the pump
test as above
• once ensured the correct liquid flowing, restore the original hose
• if necessary, control the correct liquid flowing at the intermediary levels, i.e
wire feeder unit rear and front
12. COMMUNICATION WITH THE EXTERNAL WIRE FEEDER
The external wire feeder can be connected to the connectors of the back panel of the
machine, the machine recognise the wire feeder and starts to communicate.
The control from the machine is passed to the wire feeder when the torch switch
of the wire feeder is pressed or when one of the pushbuttons of the wire feeder is
touched.
When an error in the communication between the machine and the wire feeder appear, the two display of the wire feeder show thee lines instead the values, this problem often occurs when the interconnecting cable connectors are loose or internal
wires of the interconnecting cable are open.
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