Magmaweld RD 250 TW DC User manual

Brand
Magmaweld
Model
RD 250 TW DC
Category
Welding System
Type
User manual
USER MANUAL
RD 250 TW DC
RD 400 TW DC
TIG WELDING MACHINE
www.magmaweld.com
SAFETY RULES ................................................................................................................................................3
CONTENTS
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1RD 250 TW DC / RD 400 TW DC
2.4.1
2.5.1
2.5.5
ELECTROMAGNETIC COMPATIBILITY
1. TECHNICAL INFORMATION
1.1 GENERAL EXPLANATIONS
1.2 APPLICATION AREA
1.3 DATA PLATE
1.4 TECHNICAL SPECIFICATIONS
1.5 ACCESSORIES
2. INSTALLATION
2.1 UPON RECEIPT AND CLAIMS
2.2 WORK AREA
2.3 COMPONENTS OF THE MACHINE
2.4 INSTALLATION FOR STICK ELECTRODE
Connect The Electrode Cable
2.4.2 Connect The Cable of The Earth Clamp
2.4.3 Fasten The Earth Clamp
2.4.4 Connect The Power Supply
2.5 INSTALLATION FOR TIG WELDING
Connect The TIG Torch
2.5.2 Make The Connections of The Torch Connector
2.5.3 Insert The Tungsten Electrode
2.5.4
Fasten The Earth Clamp
2.5.6 Connect The Power Supply
2.5.7 Connect The Shielding Gas Cylinder
Connect The Cable of The Earth Clamp
IDENTIFYING SAFETY INFORMATION
UNDERSTANDING THE SAFETY WARNINGS
These symbols are being used to identify potential risks.
When seen a safety symbol in the manual, it must be understood that there is an injury risk and following
instructions must be read carefully to avoid potential risks.
While welding, keep the third persons and especially the children away from the work area.
Read carefully the manual and the labels and the safety warnings on the machine.
Make sure that the warning labels positioned on your machine are in good order. Renew the damaged and the
missing labels.
Learn to operate the machine and how to make the controls properly.
Operate your machine in convenient work areas. Improper modifications affect the safety of your machine
negatively and shorten its lifetime.
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2 RD 250 TW DC / RD 400 TW DC
3. USAGE
3.1 CONTROL PANEL
3.2 MENU STRUCTURE
3.2.1 Stick Electrode Welding Process
3.2.2 TIG Welding Process
3.2.3 Usage of TIG Welding Modes
3.2.4 Error Message
3.3 CURRENT CIRCUIT
4. MAINTENANCE AND TROUBLESHOOTING
4.1 PERIODIC MAINTENANCE
4.2 NONPERIODIC MAINTENANCE
APPENDIX
APPENDIX 1: SPARE PARTS FOR RD 250 TW DC / RD 400 TW
APPENDIX 1: ELECTRICAL DIAGRAM FOR RD 250 TW DC / RD 400 TW DC
CONTENTS
3RD 250 TW DC / RD 400 TW DC
SAFETY RULES
ELECTRICAL SHOCK COULD BE FATAL
BREATHING WELDING FUMES CAN BE HAZARDOUS TO YOUR HEALTH
Installation procedure must comply with national electricity standards and other relevant
regulations and ensure that installation is performed by qualified persons.
Inhaling fumes and gases over a long period of time, generated during welding is dangerous and
forbidden .
Wear dry, hole-free insulating gloves and body protection.
Do not touch electrode with bare hand. Do not wear wet or damaged gloves and
body protection.
Do not touch live electrical parts
Never touch electrode while in contact with working surface, ground or another
electrode which is connected to a different machine
.
.
Irritation of the eyes, nose and throat are symptoms of inadequate ventilation. Take
immediate steps to improve ventilation. Do not continue welding if symptoms
persist
Install a natural or forced air ventilation system in the work area
Install an adequate ventilation system in the welding and cutting area, if needed
install a system that can remove the fume and vapor accumulated in the entire work
area, to prevent pollution use adequate filtration in discharge
In the event of welding in small, confined places, or welding lead, beryllium,
cadmium, zinc, zinc coated or painted materials; also wear a fresh air supplied
respirator in addition to the above mentioned rules
Always have a trained watchperson nearby, while working in small confined places.
Avoid working in such confined places if possible
If gas cylinders are grouped in a different area, make sure that it is a well-ventilated
area. When not being used, turn off the main cylinder valve and watch out for gas
leakage
Shielding gasses such as argon is denser than air and when being used in confined
places, can be inhaled in place of air, and this is dangerous for your health
Do not perform welding operations near chlorinated hydrocarbon vapors produced
by degreasing or painting
.
.
.
.
.
.
.
.
Protect yourself from electric shock by insulating yourself from work and ground.
Use non-flammable, dry insulating material if possible, or use dry rubber mats, dry
wood or plywood, or other dry insulating material big enough to cover your full area
of contact with the work or ground, and watch for fire.
Never connect up more than 1 electrodes or wires to the machine.
Turn off the machine, when not in use
Disconnect input plug or power before working on machine.
Frequently inspect input power cord for damage or bare wiring - repair or replace
cord immediately if damaged.
Be sure input ground wire is properly connected to a ground terminal in disconnect
box or receptacle
.
.
4 RD 250 TW DC / RD 400 TW DC
ARC RAYS CAN BURN EYES AND SKIN
FLYING METALS CAN INJURE EYES
NOISE CAN DAMAGE HEARING
HOT PARTS CAN CAUSE SEVERE BURNS
MOVING PARTS CAN CAUSE INJURY
WORKING IN SMALL AND CONFINED PLACES CAN BE DANGEROUS
Use adequate welding helmet with correct shade of filter (4 or 13 considering TS EN
379) to protect your eyes and face
Protect open parts of your body (arms, neck and ears) from arc rays by adequate
protective clothing
To protect others by arc rays and hot metals, surround the working area with flame
proof curtains which are higher than eye level and put up warning boards.
.
.
Welding, wire brushing and grinding cause sparks and flying metal.
To prevent injuries wear appropriate safety glasses with side shields even under your welding helmet .
Noise from certain industrial processes or equipments can damage hearing.
Wear approved ear protection if noise level is high.
Do not touch hot parts
Allow cooling time before servicing
hot parts, use appropriate tool, insulating gloves and fireproof clothes.
.
.
If needed to hold
Keep away from moving parts
Keep all doors, panels, and guards closed and secured
Wear shoes with metal protection over the fingers.
.
.
While welding and cutting in small, confined places, always have a trained watchperson nearby
Avoid working in such confined places
.
.
SAFETY RULES
5RD 250 TW DC / RD 400 TW DC
WELDING CAN CAUSE FIRE OR EXPLOSION
Never weld near flammable material. It may cause fire or explosions.
Before starting to weld, move flammables away or protect them with flame-proof
covers.
Do not weld on and cut closed tubes or pipes
Before welding on closed containers, open and clear them entirely. Welding
operations on these parts must be performed with the utmost caution
Never weld containers or pipes containing or which have contained substances
that could give rise to explosions
.
.
.
Welding equipments warms up so never position them on flammable surfaces.
Welding sparks can cause fire. For that reason, keep extinguishing means, such
as fire extinguishers, water and sand easy reach
Have and maintain security valves, regulators and other valves on the flammable,
explosive and compressed gas circuits in good condition by periodical controls,
used for welding and cutting operations
.
.
FALLING UNIT CAN CAUSE INJURY
Wrong positioned power source or other equipment may cause serious injury to persons or damage
to objects.
While repositioning the power source always carry by using the lifting eye. Never pull cable, hose or torch.
Always carry the gas cylinders separately
Before carrying the welding and cutting equipment, disassemble all the connections between and
separately carry the small ones by handgrips and the big ones by lifting eyes or by using appropriate
vehicles like forklifts
Install your machine on flat platforms having maximum 10 that it does not fall over. Install it on well
ventilated, non-confined places away from the dust, also avoiding the risk of falling caused by cables and
hoses. For gas cylinders not to fall over, attach it to the mobile machine or to the wall with a chain
Ensure that operators easily reach the controls and connections on the machine.
.
.
° slope
.
WELDING WIRE MAY CAUSE INJURY
Do not point the torch toward any part of a human body, other persons or any type of metal when unwinding
welding wire
While extracting the wire from the spool by hand, it may spring suddenly and injure you or a nearby person,
protect especially your eyes and face.
Make sure that there is no one close
.
.
SAFETY RULES
6 RD 250 TW DC / RD 400 TW DC
OVERUSE CAN CAUSE OVERHEATING
ARC WELDING CAN CAUSE INTERFERENCE
STATIC (ESD) CAN DAMAGE PC BOARDS
Allow cooling period; follow rated duty cycle
Reduce current or reduce duty cycle before starting to weld again
Do not block airflow to unit.
Do not filter airflow to unit without the approval of manufacturer
.
.
.
Electromagnetic energy arising during welding and cutting operations can interfere with sensitive
electronic equipment such as microprocessors, computers, and computer-driven equipment such as
robots
Be sure all equipment in the welding area is electromagnetically compatible
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such
as on the floor
To avoid possible EMC damages, locate welding operation as far as possible (100 meters) from any
sensitive electronic equipment
Be sure this welding machine is installed and grounded according to this manual
If interference still occurs, the user must take extra measures such as moving the welding machine, using
shielded cables, using line filters, or shielding the work area
.
.
.
.
.
.
Put on grounded wrist strap before handling boards or parts
Use proper static-proof bags and boxes to store, move, or ship PC boards
.
.
PROTECTION
Do not expose the welding machine to rain, protect from water drops and vapour.
LIFETIME
The lifetime determined by Ministry of Industry and Trade is 10 years.
OBEY ALL THE SAFETY RULES
STATED IN THE MANUAL!
MAINTENANCE MADE BY UNQUALIFIED PERSONS MAY CAUSE INJURIES
Electrical devices should not be repaired by unqualified persons. Improper repairs can cause serious
injuries or even death during applications
The components of the gas circuit works under pressure. The service given by unqualified persons may
cause explosions and operators can be injured seriously
.
.
SAFETY RULES
7RD 250 TW DC / RD 400 TW DC
All electrical equipment generates small amounts of electromagnetic emission due to current transferring
in the equipment. Electrical emission may be transmitted through power lines or radiated through space,
similar to a radio transmitter. When emissions are received by other equipment, electrical interference may
result . Electrical emissions may affect not only welding machines but also many kinds of electrical
equipment like radio and TV reception, numerical controlled machines, telephone systems, computers etc.
.
.
.
.
.
Welding and cutting machines have been designed to work for professional and industrial use; for other
applications to contact the manufacturers
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of
the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some
cases this remedial action may be as simple as earthing the welding the welding circuit, in other cases it
could involve constructing an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome
The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements
should only be authorized by a person who is competent to assess whether the changes will increase the
risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of
other equipment
Extra precaution may be required when the welding power source is used in a domestic establishment
Special measures shall be taken to achieve compliance with welding power source including HF frequency
for arc ignition and stabilizing; it may be required use of shielded cables and in any case to resolve the
particular implementation (e.g. with robot, computer and any other electrical and electronic equipment
connected to welding power source) to call the technical assistance of the manufacturer
Before installing the welding equipment, the user shall make an assessment of potential electromagnetic
problems in the surrounding area. The following shall be taken into account- if needed arrange the working
hours that not coincide with those
Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment
Radio and television transmitters and receivers
Computer and other control equipment
Safety critical equipment,
Presence of heart beat regulators, heart cells, hearing devices or etc. nearby,
Equipment used for calibration or measurement,
The immunity of other equipment in the environment.
The user shall ensure that other equipment being used in the environment is compatible. This may require
additional protection measures
.
,
,
,
.
Welding equipment should be connected to the mains supply according to the manufacturer’s
recommendations. OERLIKON welding machines are filtered against emission according to standards. If
interference still occurs, it may be necessary to take additional precautions such as filtering of the mains
supply.
The welding equipment should be routinely maintained according to the manufacturer’s
recommendations. The welding equipment should not be modified without the approval of manufacturer.
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to the floor level. Power cables and signal cables should be kept separately.
Keeping cables in the shape of -8- and taping together reduce emission.
Connect earth clamp to workpiece as close to the weld as possible. But the user should be control whether
this situation damage to people and equipment or not.
ELECTROMAGNETIC COMPATIBILITY (EMC)
ELECTROMAGNETIC EMISSION
ASSESMENT OF THE SURROUNDING AREA
METHODS OF REDUCING EMISSIONS
1. TECHNICAL INFORMATION
1.1 GENERAL EXPLANATIONS
1.2 APPLICATION AREA
RD 250 TW DC and RD 400 TW DC welding
machines are good choices for workshops, factories
and work areas which manifacture non-stop all day.
They are used for welding stainless steel, nickel and
its alloys, titanium and carbon steel.
Easy monitoring of welding paremeters with digital
display.
Fan-cooled and thermally protected against
overloading.
Factory installed running gear/cylinder rack for better
mobility in the workshop.
RD 250 TW and RD 400 TW are water-cooled
industrial DC TIG with Pulse and MMA welding
machines.
Easy arc striking with HF.
Enhanced professional TIG controls; such a pre-gas,
slope up, pulse, slope down, post gas & crater filling.
Up to 10 program storage.
1.3 DATA PLATE
3 Phase Transformer Rectifier
Drooping Characteristic
Appropriate To Operate In Dangerous Work Area
Line Input 3 Phase Alternative Current
Fuse
TIG Welding
Direct Current
8 RD 250 TW DC / RD 400 TW DC
Duty Cycle
1 2
Temperature ( C)°
Time (min.)
6 min. 6 min. 6 min.4 min. 4 min. 4 min.
Duty cycle defines the percentage of welding time out of a period of 10 minutes at a given current. For example,
a 250A. Welder with a 60% duty cycle must be rested (2) for 4 minutes, after 6 minutes of continuous welding
(1). If the unit overheats, thermostats will open and welding will stop. Wait for the unit to cool down. In this case
ambient temperature might be over 40ºC, therefore either reduce the current or work with lower duty cycle.
Exceeding duty cycle can damage unit and void warranty.
TECHNICAL INFORMATION
X :
U :
U :
U :
I :
I :
IP 22 :
0
1
2
1
2
S :Input Power1
Duty Cycle*
Open Circuit Voltage
Line Voltage and Frequency
Rated Welding Voltage
Input Current
Rated Welding Current
Protection Class
10 A / 20,4 V - 400 A / 36 V
X35 % 60 % 100 %
305 A 235 A
32 V 29 V
CL.I. H
U V
380
50 Hz
1
S1
IP 22
I A
29
1I A
22
1I A
38
1
19 kVA 14 kVA
S
T 40 A
U V
64
0I2
U2
3R
25 kVA
400 A
36 V
R 400 TWD DC PULSE
Seri No :
EN 60974-1
EN 60974-10
MAGMA MEKATRONİK MAKİNE SAN. VE TİC. A.Ş.
Organize Sanayi Bölgesi 5. Kısım Manisa-TÜRKİYE
3R
S
UNIT
TECHNICAL DATA RD 250 TW DC RD 400 TW DC
POWER SOURCEI
Line Voltage (3 Phases)
Input Power (%35)
Input Current (%35)
Recommended Line Fuses
Rated Welding Current (%35)
Open Circuit Voltage
Welding Current Range
Protection Class (EN 60 529)
Dimensions (LxWxH)
Weight
Water Tank Capacity
Dimensions (LxWxH)
Weight (Without water)
kVA
A
A
A
V
A
IP
mm
kg
lt
mm
kg
380 V / 50 - 60 Hz
??
22.4
3x25
250
64
10 - 250
IP22
1030x590x730
115
6,5
760x440x170
34
380 V / 50 - 60 Hz
25
38
3x40
400
64
10 - 400
IP22
1030x590x730
130
6,5
760x440x170
34
1.4 TECHNICAL SPECIFICATIONS
1.5 ACCESSORIES
STANDARD ACCESSORIES
Earth Clamp and Cable
Torch (350A)
RD 250 TW DC RD 400 TW DC
Pressure Regulator
9RD 250 TW DC / RD 400 TW DC
TECHNICAL INFORMATION
COOLING SYSTEM
51900313015190031301
K301100605 (35mm - 3m)
2
K301100303 (25mm - 3m)
2
A259001002 A259001002
10 RD 250 TW DC / RD 400 TW DC
INSTALLATION
Ensure that you have received all the items that
you have ordered. In case there is any missing or
damaged items, contact your supplier
immediately.
In the event of damaged or missing delivery;
it to the shipping agency and OERLIKON
with the photocopy of shipping bill.
(Oerlikon Fax: +90 236 226 27 28)
draw
up a record, take a photo of the damage and
report
ú
ú
ú
ú
ú
Be sure that none of the following 5 items are
missing in the box:
The machine, together with its line cable
TIG Torch
Welding cable and holder
Earth cable and clamp
Certificate and user manual
2. INSTALLATION
2.1 UPON RECEIPT AND CLAIMS
In order to cool down the machine and have an
efficient work, keep the machine at least 30 cm
away from the surrounding objects. Do not place
any heat source, as oven, to front side of the
machine where the cooling air is taken from.
Welding machine must not be effected of heat
directly.
Do not place the machine in small and narrow
places. Beware of excessive dust and dirt.
Keep your machine away from wet and humid
places.
Please use a suitable exhaust system for gases
and cutting vapours. Use breathing apparatus if
there is a risk of inhaling any welding or cutting
vapours.
Do not operate the machine under direct sunlight,
rain and wind. Machines should be operated on
lower capacities when ambient air temperature
exceeds 40ºC.
2.2 WORK AREA
Transport and place the device on firm and level
ground so that it may not fall over. The maximum
permissible angle of inclination for transport and
assembly is 10°.
This machine is protected electronically against
overloading. Do not use stronger fuses than those
stated on the data plate of the device.
Ensure that the work clamp has good and direct
contact near the welding location. Do not direct
welding current over chains, ball bearings, steel
cables, protection conductors etc., Otherwise they
may melt.
Ensure that operators can easily reach the
machine controls and equipment connections.
Use lifting eyes for lifting the machine. Do not lift
the machine by using a fork-lift or a similar vehicle.
Avoid welding where air-flow is high. Protect the
welding area with curtains or mobile screens.
2.3 COMPONENTS OF THE MACHINE
Positive Pole
Negative Pole
Gas Outlet Bush
TIG Torch Connector
Control Panel
Cold Water Supply
Hot Water Return
Water Cooling Unit Mains Lamp
Water Level Indicator
Power Switch
1
2
3
4
5
6
7
8
9
10
Gas Supply Inlet
Connection Socket of Water Cooling Unit
Control Cable of Water Cooling Unit
Fuse of Water Cooling Unit
Fuses of Power Source
Mains Cable
Ventilator Grille
Handle
Lifting
Wheel
11
12
13
14
15
16
17
18
19
20
6
7
8
9
18
19
20
5
14
16
15
11
10
17
13
12
Figure 2: RD 400 TW DC Back ViewFigure 1: RD 400 TW DC Front View
2
3
4
1
11RD 250 TW DC / RD 400 TW DC
INSTALLATION
2.4 INSTALLATION FOR STICK ELECTRODE
2.5 INSTALLATION FOR TIG WELDING
Danger due to electric shock!
Due to HF-ignition, a high ignition
voltage is present at the torch.
Never touch the welding electrode
or parts conducting welding
current when the device is switched on.
2.5.1 Connect The TIG Torch
Connect the TIG torch to the negative socket
and secure it by turning it to the right.
Connect the torch's gas line to the gas outlet bush
Torç kontrol kablosunu, torç soketine takın.
(2)
(3). (4)
Only the control cable of a torch may be
connected to the torch connector .(4)
2.5.2 Make The Connections of The Torch
Connector
When the device is switched on,
avoid torch to come into contact
with the machine. Otherwise high
voltage of HF ignition will be carried
via the electronical boards and it will
destroy these.
12 RD 250 TW DC / RD 400 TW DC
INSTALLATION
2.4.1 Connect The Electrode Cable
Connect the electrode cable to the minus or
plus socket and secure the cable by turning it to
the right.
Heed the electrode manufacturer's
instructions.
(2)
(1)
2.4.2 Connect The Cable of The Earth Clamp
Connect the cable of the earth clamp to the free
minus or plus socket and secure the cable
by turning it to the right.
(2) (1)
2.4.3 Fasten The Earth Clamp
Do not place the earth clamp on the
welding machine or the gas cylinder;
otherwise the welding current will be
carried via the protective conductors
and it will destroy these.
The mains voltage and tolerance as well
as the fuse protection must correspond to
the technical specifications. (see
Technical Data)
The machine is suitable for operation on the mains
supply or on a current generator.
Plug the mains plug into the appropriate socket.
2.4.4 Connect The Power Supply
Figure 4: Incorrect Connection of The Earth Clamp
Mount the earth clamp in the immediate
vicinity of the welding point such that the welding
current cannot find its own way via machine
components, ball bearings or electrical circuits.
(13)
Connect the earth clamp firmly to the welding
bench or the workpiece.
Figure 3: Connecting The Earth Clamp
Incorrect !
Correct !
Figure 5: Torch Connections
5
1
23
4
1 2 (4)
5
(4)
3 4
and numbered holes of torch connector
are for cables of torch switches. numbered
hole of torch connector is for earth cable.
and numbered holes arent active, so they
will not be connected.
2.5.3 Insert The Tungsten Electrode
Figure 6: Inserting The Tungsten Electrode
21
22
23
24
25
Electrode
Clamping Cap
Clamping Sleeve
Collet Body
Nozzle
Unscrew the clamping cap .
Remove the electrode from the clamping
sleeve .
Grind the end of the electrode .
Slide the electrode into the collet .
Insert the electrode into the torch and screw the
clamping cap down tight.
(22)
(21)
(23)
(21)
(21) (23)
(21)
(22)
21
22
23
24
25
2.5.4 Connect The Cable of The Earth Clamp
Do not disassemble the collet body
and the gas nozzle .
When converting the torch to another electrode
diameter, please observe the following:
The collet , collet body and
electrode must have the same
diameter.
The gas nozzle must be matched to
the electrode diameter.
(24)
(25)
(23) (24)
(21)
(25)
Connect the cable of the earth clamp to the positive
socket and secure it by turning it to the right.(1)
2.5.5 Fasten The Earth Clamp
Mount the earth clamp in the immediate vicinity of
the welding point such that the welding current
cannot find its own way via machine components,
ball bearings or electrical circuits.
Connect the earth clamp firmly to the welding bench
or the workpiece.
Figure 7: Connecting The Earth Clamp
Do not place the earth clamp on the
welding machine or the gas cylinder;
otherwise the welding current will be
carried via the protective conductors
and it will destroy these.
Figure 8: Incorrect Connection of The Earth Clamp
2.5.7 Connect The Shielding Gas Cylinder
Figurel 9: Shielding Gas Cylinder
The mains voltage and tolerance as well
as the fuse protection must correspond to
the technical specifications. (See
Technical Data)
The machine is suitable for operation on the mains
supply or on a current generator.
Plug the mains plug into the appropriate socket.
2.5.6 Connect The Power Supply
26
27
28
29
30
31
32
33
Secure the shielding gas cylinder ,e.g. by using
a securing chain .
Briefly open the gas cylinder valve several
times in order to blow out any dirt particles present.
Connect the pressure reducer to the shielding
gas cylinder .
Screw the shielding gas hose onto the
pressure reducer and open the shielding gas
cylinder .
Start the "gas test" and set the gas quantity with the
setting screw of the pressure reducer. The gas
quantity is indicated on the flowmeter .
Gas nozzle size = litres/min.
The cylinder content is indicated on
the content manometer .
(29)
(28)
(26)
(31)
(27)
(32)
(31)
(27)
(33)
(30)
Rule of thumb:
(29)
26
27
28
29
Gas Cylinder Valve
Shielding Gas Cylinder
Securing Chain
Manometer
30
31
32
33
Flowmeter
Pressure Reducer
Gas Hose
Pressure Setting Screw
13RD 250 TW DC / RD 400 TW DC
Incorrect !
Correct !
3.1 CONTROL PANEL
1 Multifunctional Knob :
2 Mutlifunctional Display :
3 Program Selection Button :
4 Program Display :
5 Welding Mode Selection Button :
6 LED Stick Electrode :
7 LED 2-Stroke :
8 LED 4-Stroke :
:
10 (DC TIG with Pulse)/(DC TIG) Selection
Button :
is used for selecting
and adjusting welding parameters. Parameters
are selected by pushing the knob. LED of the
selected parameter turns on. By turning the
knob clockwise, selected welding parameter
increases and it decreases by turning the knob
counter clockwise.
displays the value of
the welding parameter which is selected by
multifunctional knob. Plus it displays the
welding current value during welding.
is used for
selecting a program among 0-9 numbered
programs.
displays the number of the
selected program.
is used for
selecting one of these welding modes;
Stick electrode welding, 2-stroke TIG welding,
4-stroke TIG welding, spotTIG welding.
is selected by pushing
welding mode selection button. While LED is
turned on, machine is in stick electrode welding
mode. HF-ignition is inactive in this mode.
is selected by pushing welding
mode selection button. While LED is turned on,
machine is in LED 2-Stroke TIG welding mode.
is selected by pushing welding
mode selection button. While LED is turned on,
machine is in LED 4-Stroke TIG welding mode.
is selected by pushing
welding mode selection button. While LED is
turned on, machine is in spot TIG welding mode.
is used for selecting one of the modes
“DC TIG with Pulse”and “DC TIG”.
9 LED Spot Welding
11 LED DC TIG with PULSE :
12 LED DC TIG :
13 LED Gas Pre-Flow Time :
14 LED Start Current:
15 LED Upslope Time :
16 LED Main Current :
17 LED Secondary Current :
18 LED PULSE Frequency :
19 LED Spot Time :
20 LED Downslope Time :
is turns on if DC TIG
welding with PULSE is selected.
is turns on if DC TIG welding is
selected.
is selected by
pushing multifunctional knob. While LED is
turned on, the desired value is adjusted by
turning the multifunctional knob.
is selected by pushing
multifunctional knob. While LED is turned on,
the desired value is adjusted by turning the
multifunctional knob.
is selected by pushing
multifunctional knob. While LED is turned on,
the desired value is adjusted by turning the
multifunctional knob.
is selected by pushing
multifunctional knob. While LED is turned on,
the desired value is adjusted by turning the
multifunctional knob.
is selected by
pushing multifunctional knob. While LED is
turned on, the desired value is adjusted by
turning the multifunctional knob.
is selected by
pushing multifunctional knob. While LED is
turned on, the desired value is adjusted by
turning the multifunctional knob.
is selected by pushing
multifunctional knob. While LED is turned on,
the desired value is adjusted by turning the
multifunctional knob.
is selected by pushing
multifunctional knob. While LED is turned on,
the desired value is adjusted by turning the
multifunctional knob.
23
1
6
7
8
9
5
11
12
13
14
15
16
17 18
19
20
21
22
4
10
14 RD 250 TW DC / RD 400 TW DC
USAGE
3. USAGE
PARAMETER RANGE FACTORY
SETTING LED
2-Stroke
TIG
Stick
Electrode
4-Stroke
TIG
Spot
TIG
1 sec
1 sec
80 A
5 sec
40 A
20 A
15 Hz
1 sec
2 sec
13
15
17
19
21
14
18
20
22
130 A
130 A
16
16
0.1 - 15 Hz
0.1 - 10 sec
10 - 250 A
0.1 - 10 sec
10 - 250 A
10 - 250 A
0.1 - 10 sec
1 - 23 sec
0.1 - 10 sec
10 - 250 A
10 - 400 A
Upslope Time
Main Current ( )RD 250 TW
Main Current ( )RD 400 TW
Spot Time
Downslope Time
Pre-Gas Flow Time
Start Current
Post-Gas Flow Time
Secondary Current
Final Current
Frequency
DC DC DC
Pulse Pulse Pulse
P PPPPPP
PPPPPP
PPPPPP
PPPPPP
PPPPPP
PPPPPP
PPPPPP
PPPPPP
PP
P P
P
P P
P
P
P
P
3.2 MENU STRUCTURE
USAGE
3.2.1 Stick Electrode Welding Process
Select the stick electrode welding mode by
pushing the welding mode selection button .
LED stick electrode lights up.
In this mode, LED main current lights up and
only main current can be adjusted. Program
numbers and welding parameters are inactive.
Adjust the desired current value by turning the
multifunctional knob.
Machine is ready for stick electrode welding.
(5)
(6)
(16)
3.2.2 TIG Welding Process
Push the program selection button for selecting
a previously adjusted program or changing its
parameters.
Push the welding mode selection button for
selecting one of the TIG welding modes; 2-stroke
TIG welding, 4-stroke TIG welding, spot TIG
welding.
Push the (DC TIG with Pulse)/(DC TIG) selection
button for selecting “DC TIG with Pulse”or
“DC TIG”.
Push the multifunctional button for selecting
the desired welding parameter.
After the LED of the desired parameter lights up,
adjust the value of the parameter by turning the
multifunctional button . By turning the knob
clockwise, the welding parameter increases and it
decreases by turning the knob counter clockwise.
Latest adjusted parameter values will be saved
automatically. There is no need to do anything else
for saving the settings.
For using the saved program or readjusting any
parameter of it, push the program selection button
.
(3)
(5)
(10)
(1)
(1)
(3)
Danger due to electric shock!
Due to HF-ignition, a high ignition
voltage is present at the torch.
Never touch the welding electrode
or parts conducting welding current
when the device is switched on.
TIG welding parameters can be saved in 10
programs which are numbered between 0-9.
In first use, all parameters of all programs
are in factory settings which are shown in
the table.
15RD 250 TW DC / RD 400 TW DC
21 LED Final Current : is selected by pushing
multifunctional knob. While LED is turned on,
the desired value is adjusted by turning the
multifunctional knob.
22 LED Gas Post-Flow Time : is selected by
pushing multifunctional knob. While LED is
turned on, the desired value is adjusted by
turning the multifunctional knob.
(DC TIG with PULSE) / (DC TIG)
(10)
(10)
In order to use those 3 TIG welding modes with
Pulse function, select the “DC TIG with Pulse”
mode with the (DC TIG with Pulse)/(DC TIG)
selection button . Welding current changes
continuously between main current and
secondary current in Pulse frequency.
In order to use those 3 TIG welding modes without
Pulse function, select the “DC TIG”mode with the
(DC TIG with Pulse)/(DC TIG) selection button
. Welding current is only main current in this
mode.
Gas
Pre-Flow
Start
Current
Current
Upslope
Current
Downslope
Final
Current
Gas
Post-Flow
*Pulse
Frequency
***Secondary
Current
Main
Current
Main
Current
**Spot Welding Time
3.3 CURRENT CIRCUIT
3.2.3 Usage of TIG Welding Modes
3.2.4 Error Message
When the machine overheats, an error message
(“ ”) appears on multifunctional digital display
and numbered LED flashes.
In this case, wait for the machine to cool and the
error message to disappear.
Err
(2) 16
* Only in TIG with PULSE
** Only in Spot mode
*** In all TIG modes except 2-Stroke DC TIG
16 RD 250 TW DC / RD 400 TW DC
USAGE
2-Stroke TIG Welding
4-Stroke TIG Welding
Spot TIG Welding
Push the torch trigger and keep it pushed. Current
starts with start current after pre-flow gas and
increases during upslope and reaches to value of
main current.
Welding goes on with main current as long as torch
trigger is kept pushed. After leaving the trigger,
current decreases during downslope and reaches to
final current before post-flow gas.
Push the torch trigger. Current starts with start
current after pre-flow gas and increases during
upslope and reaches to value of main current.
Welding goes on with main current as long as torch
trigger is pushed again.
If the torch trigger is pushed less than 1 second,
current passes to secondary current value and it
goes back to main current value if the torch trigger is
pushed less than 1 second again.
If the torch trigger is pushed more than 1 second, in
both main current and secondary current, current
decreases during downslope and reaches to final
current before post-flow gas.
Push the torch trigger. Current starts with start
current after pre-flow gas and increases during
upslope and reaches to value of main current.
Welding goes on during spot welding time. After
spot welding time is over, current decreases during
downslope and reaches to final current before post-
flow gas.
17RD 250 TW DC / RD 400 TW DC
MAINTENANCE AND TROUBLESHOOTING
4. MAINTENANCE AND TROUBLESHOOTING
4.2 NONPERIODIC MAINTENANCE
Clean the consumables on torch such as nozzle and contact tip.
Replace them if needed.
Use only original consumables to ensure trouble-free long-term
operation.
Before removing any screw on the machine for maintenance, power supply
must be disconnected from the electric lines and enough time should be
allowed for capacitor discharging. During maintenance, pay attention to the
moving parts in the machine such as ventilator.
4.1 PERIODIC MAINTENANCE
Clean the labels on the
ma ch ine . Rep ai r or
replace the worn out
labels.
Repair or replace the worn
out welding cables.
Check cables of TIG torch,
electrod holder and work
clamp.
Once every three months
NOTE: The above recommended maintenance periods are indicative according to our general
experience, these may vary from work shop to work shop and the conditions of the welding site.
Use only original spare parts for maintenance and repair.
If you experience problems or need repairs, contact a authorised dealer.
Never make repairs or technical changes yourself. In this case the manufacturer's warranty is no
longer valid.
Check the dust filter:
-Switch the machine off.
-Unplug the mains plug.
-Unscrew the ventilation grid on the rear side.
-Check the dust filter for pollution.
-Replace the dust filter if it is polluted .
APPENDIX 1
SPARE PARTS FOR RD 250 TW DC / RD 400 TW
Gas Ventile 1/4”- 230 VAC
Gas Ventile Gland
Gas Gland - Male R1/4
Glass Fuse Socket - 20x5mm
Relay - 220VAC/10A
Relay Socket
Hall Effect Sensor - 400A
Control Transformer - 220 - 15V
Connector
Stone Resistor - 150W / 80 Ohm
Wire-wound Resistor - 250W
Knob - Big
Temperature Limiting Switch 125 Degrees
Changeover Switch 32A
Cooling Fan
HF Generator - DC - Black Box
EMC Filter
Rectifier PTH450DV-A-ST30
TIG Function Board
Filter Board
HF Filter
Electronic Board - E101A
Welding Socket
Impedance Coil
Main Transformer
Primary - Secondary Spool
Swivel Plastic Wheel
Plastic Wheel
Bakalite U-Arm
Quick Coupling - 1/2”Blue
Quick Coupling - 1/2”Red
Fan
Signal Lamp - Neon
Water Tank
Radiator
Water Pump
MATERIAL CODE DESCRIPTION
18 RD 250 TW DC / RD 400 TW DC
A253200003
A256400004
A256400007
A300190001
A312100004
A312900002
A830900008
A366100002
A378002002
A410200004
A410500002
A229500002
A314800102
A308033004
A250200002
Y514000020
A490400001
A430902002
K405000036
K405000044
A490900001
K405000068
A377900106
K304500016
K304000020
K302200008
A225220010
A225222012
A229102002
A245700002.
A245700003
A250900001
A310310002
A249000003
A260000004
A240000004
APPENDIX 2
ELECTRICAL DIAGRAM FOR RD 250 TW DC / RD 400 TW DC
19RD 250 TW DC / RD 400 TW DC
Earth
C1
Finder 230VAC
8R/250W
80R 150W
HF Bobini
Şok Bobini
+
-
HF TYPE-E
Br1
E101A
18
19
20
2
17
16
15
14
13
12
9
11
Termik
R1
S1
T1
N1
KR
GR
KS
GS
KT
GT
E501APW
P1-4 4
P1-1
P1-2
P1-3
P1-6
R1
S1
T1
N1
P4-10 T
P4-9 N
P4-1
P4-2
P4-5
P4-6
P4-5
P4-6
P4-5
P4-6
220VAC
P4-7
P4-8
P3-1
P3-2
TORCH
M1
K2
K4
4 3 2 1
4 3 2 1
F2
F1
M2
F1
SD13
K1 K3
4 3 2 1
4 3 2 1
P3-3
P3-4
Th Wf
60.13.8.230.0040
21
22
S1
P4-3
P4-4
TIG Filtre Kart›
J3-3
J3-2
J3-1
J3-4
J3-5
J3-6
J3-7
Earth
1
6
11 9
7
3
2 10
1 2 3 4
400A/4V
4
4
4
1
2
3
4
J3
P4
P2
8
E501ACNT
P1-2
P1-1
P1-3
T2
220V/15VAC
T1
F3
P1-5 6
Hall Sensor
PTH450DV-A-ST30
0
18VAC
18VAC
18VAC
V1
C2
Finder 230VAC
P4-5
P4-6
40.51.8.230.0000
R
S
T
N
EMI Filter
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Magmaweld RD 250 TW DC User manual

Brand
Magmaweld
Model
RD 250 TW DC
Category
Welding System
Type
User manual
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