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WECO Cruiser 502AC/DC User manual

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Cod. 006.0001.1820
25/05/2018 V.2.6
Cruiser 322AC/DC
Power Pulse 402AC/DC
502AC/DC
Instruction manual
ENG
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6 Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
2
ENGLISH
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6
Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
3
ENGLISH
INDEX
1 INTRODUCTION .......................................................................................................................................... 4
1.1 INTRODUCTION .......................................................................................................................................... 5
2 INSTALLATION .......................................................................................................................................... 6
2.1 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK ...................................................................... 6
2.2 FRONT PANEL ............................................................................................................................................. 6
2.3 REAR PANEL ............................................................................................................................................... 7
2.4 PREPARING FOR MMA WELDING ............................................................................................................. 8
2.5 PREPARING FOR TIG WELDING ............................................................................................................... 9
3 USER INTERFACE .................................................................................................................................... 10
4 UNIT POWER-UP ......................................................................................................................................13
5 RESET (LOAD FACTORY SETTINGS) ..................................................................................................... 14
6 SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE) ......................................................... 15
7 ALARM MANAGEMENT ........................................................................................................................... 18
8 MMA WELDING ........................................................................................................................................ 20
8.1 TIG WELDING/GOUGING - FIRST LEVEL MENU .................................................................................... 20
8.2 MMA /GOUGING WELDING -SECOND LEVEL MENU ............................................................................. 21
8.3 MMA WELDING - SPECIAL FUNCTIONS ................................................................................................. 23
9 TIG WELDING ........................................................................................................................................... 24
9.1 TIG WELDING - FIRST LEVEL MENU ...................................................................................................... 24
9.2 TIG WELDING - SECOND LEVEL MENU ................................................................................................. 28
9.3 TIG DC WELDING - SPECIAL FUNCTIONS MENU ................................................................................. 32
9.4 TIG AC WELDING - SPECIAL FUNCTIONS MENU .................................................................................. 35
10 TORCH TRIGGER PROCEDURE ............................................................................................................. 39
10.1 2 STROKE SPOT - Q-SPOT FUNCTION .................................................................................................. 45
11 JOBS MANAGEMENT .............................................................................................................................. 51
11.1 SAVING A JOB ........................................................................................................................................... 51
11.2 DELETING A JOB ...................................................................................................................................... 52
11.3 LOADING A JOB ........................................................................................................................................ 53
11.4 SELECTING JOBS USING THE TORCH BUTTONS ................................................................................ 53
12 TECHNICAL DATA .................................................................................................................................... 54
12.1 CRUISER 322 AC/DC - POWER PULSE 322 AC/DC................................................................................ 54
12.2 CRUISER 402 AC/DC - POWER PULSE 402 AC/DC................................................................................ 55
12.3 CRUISER 502 AC/DC - POWER PULSE 502 AC/DC................................................................................ 56
13 ELECTRICAL DIAGRAM .......................................................................................................................... 57
13.1 CRUISER 322 AC/DC - POWER PULSE 322 AC/DC................................................................................ 57
13.2 CRUISER 402/502 AC/DC - POWER PULSE 402/502 AC/DC.................................................................. 63
13.3 “REMOTE 1” CONNECTOR ...................................................................................................................... 68
13.4 “IR” CONNECTOR ..................................................................................................................................... 68
13.5 TORCH CONNECTOR (front panel) .......................................................................................................... 68
13.6 REMOTE CONTROL CONNECTOR (back panel)..................................................................................... 68
14 SPARE PARTS .......................................................................................................................................... 69
14.1 CRUISER 322 AC/DC - POWER PULSE 322 AC/DC................................................................................ 69
14.2 CRUISER 402/502 AC/DC - POWER PULSE 402/502 AC/DC.................................................................. 71
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6 Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
4
ENGLISH
1 INTRODUCTION
IMPORTANT!
This handbook must be consigned to the user prior to installation and commissioning of the unit.
Read the "General prescriptions for use" handbook supplied separately from this handbook before
installing and commissioning the unit.
The meaning of the symbols in this manual and the associated precautionary information are given in
the "General prescriptions for use”.
If the "General prescriptions for use" are not present, it is mandatory to request a replacement copy
from the manufacturer or from your dealer.
Retain these documents for future consultation.
LEGEND
DANGER!
This pictogram warns of danger of death or serious injury.
WARNING!
This pictogram warns of a risk of injury or damage to property.
CAUTION!
This pictogram warns of a potentially hazardous situation.
INFORMATION
This pictogram gives important information concerning the execution of the relevant operations.
 Thissymbolidentiesanactionthatoccursautomaticallyasaresultofapreviousaction.
 Thissymbolidentiesadditionalinformationorareferencetoadifferentsectionofthemanual
containing the associated information.
§ Thissymbolidentiesareferencetoachapterofthemanual.
*1Thesymbolreferstotheassociatednumberednote.
NOTES
Theguresinthismanualarepurelyguidelineandtheimagesmaycontaindifferenceswithrespectto
theactualequipmenttowhichtheyrefer.
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6
Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
5
ENGLISH
1.1 INTRODUCTION
ThisprofessionalandruggedweldingpowersourceforDCMMAandTIGweldingwithexceptionalarc
characteristicsisdesignedtooperateinharshenvironmentalconditionsintheeldsofprofessional
maintenance,shipyardsandoffshore,buildingconstructionandheavyfabrication.
TheARCAIRfunctionallowsperfectde-seamingwithcarbonelectrodesofupto10mmindiameter.
Upto6mmdiameterelectrodeweldingispossibleinMMA.
InMMAweldingtheHotStartandArcForcefunctionsareadjustableandtheyallowimprovedarcstrik-
ing,aatterbeadandmoreuniformweld.
TheAntiStickingfunctionmakesitpossibletodetachtheelectroderapidlyfromtheworkpieceinthe
eventofaccidentalsticking.
Theparameterspre-setintheDCTIGpulsedsynergiccurvesimplifyweldingbyregulationexclusively
ofthecurrent.
ThecurrentisadjustablealsofromtheUp-Downtorch.
Thesimplyandintuitiveinterfaceallowshighprecisionadjustmentswith50storableprograms.
Thewiderangeof adjustablepulsedfrequency incombinationwiththe complementaryparameters
(basecurrentanddutycycle)makesitpossibletoweldinslowandfastpulsedmode.
Thankstoitsmodularconguration,thepowersourcecanbeconguredforMIG/MAGweldingbyadd-
ingawirefeedunit,extension,and,ifrequired,acoolingunitandpowersourcetransporttrolley.
Fan. Thefanisturnedononlyduringwelding,attheendoftheweldingprocessitremainsonfora
xedperiodoftimeaccordingtoweldingconditions.
 Thefanisnonethelesscontrolledbyspecicthermalsensorsthatguaranteeacorrectcoolingof
the machine.
Accessories/ancillary devices that can be connected to the unit:
-UP/DOWNtorchortorchwithpotentiometertoadjusttheweldingcurrentfromadistance.
-Manualremotecontrollerforremoteadjustmentoftheweldingcurrent.
-Foot-pedalremotecontrollerforTIGtorcharcstrikingandremoteadjustmentofweldingcurrent.
 ThemaximumandminimumvalueoftheTIPweldingcurrentcanbesetusingtheremotecontrol
pedal.Ifbothremotecontrolsareconnected,theremotecontrolpedaltakesprecedenceover
theTIGUp/Downorpotentiometertorch.
-LiquidcoolergroupforTIGtorches.
-Powersourcetrolley.
Consultyourdealerforanupdatedlistofaccessoriesandthelatestnewproductsavailable.
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6 Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
6
ENGLISH
2 INSTALLATION
DANGER!
Lifting and positioning
Read the warnings highlighted by the following symbols in the “General prescriptions for use”.
2.1 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK
Themainspowersupplyfeaturestowhichtheequipmentshouldbeconnectedaregiveninchapter“12
TECHNICAL DATA” at page 54.
Themachinecanbeconnectedtomotorgeneratorsprovidedtheirvoltageisstabilised.
Connect/disconnectthevariousdeviceswiththemachineswitchedoff.
2.2 FRONT PANEL
1
7
8
2 3 4 5 6
○ Connectorforgasfeedhose:Torchpowersource[Item1].
○ ConnectorforlogicsignalsofTIGtorch[Item2].
○ Remotecontrollerconnector[Item3].
○ TIGTORCHweldingsocket[Item4].
○ Negativepoleweldingsocket[Item5].
○ Positivepoleweldingsocket[Item6].
○ WeldingpowersourceON/OFFswitch.Item7].
○ MainsprotectionONLED[Item8].ThisLEDilluminatesifanincorrectoperatingconditionoc-
curs:.
• absenceofaphaseinthepowersupplyline.
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6
Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
7
ENGLISH
2.3 REAR PANEL
1 2 3
5
8
9
4
6 7
○ Auxiliarypowersupplytransformersafetyfuse[Item1].
• Type: Delayed acting (T)
• Amperage: 2 A (3.15 A for 322AC/DC)
• Voltage: 500 V a.c.
○ Signalsconnectorforautomaticapplication[Item2].
○ Pre-heatersupplysocket(OPTIONALon322AC/DC)[Item3].
 Thesocketisinternallyprotectedbyaself-resettingfuse.
• Powersockettype:Schuko
• Maximumpower:130W
• Voltage: 230 V a.c.
○Connector for gas feed hose:
• cylinderpowersource
○ Coolergrouppowerfeedingconnector[Item5].
• Voltage: 400 V a.c.
• Currentoutput:1.0A
• IP protection rating: IP20 (cap open) / IP66 (cap closed)
DANGER!
High voltage!
If the socket is not connected to any devices always close cap 1
○ Connectorforconnectiontotheprogrammer.[Item6].(Programmingconnectorforthe"frontal
logic"circuitboard).Youcanupdatethesoftwareoftheequipmentusingtheprogrammingkit.
○ Connectorofthebundleofcablesforconnectingthepowersourcetotheremotecontroldevice.
[Item7].
○ Powercable[Item8].
• Totallength(includinginternalpart):5,0m
10
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6 Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
8
ENGLISH
• Numberandcrosssectionofwires:4x6mm2 (4 mm2 on 322AC/DC)
• Powerplugtype:notsupplied
○ Socketforconnectingthepowercablebetweenthepowersourceandtheremotecontroldevice
[Item9].
○(Only PowerPulse322/402/502AC/DC)Connectorforconnectiontotheprogrammer[Item10].
Programmingconnectorforthe“pulsed”circuitboard.Youcanupdatethesoftwareoftheequip-
mentusingtheprogrammingkit.
2.4 PREPARING FOR MMA WELDING
1. SettheweldingpowersourceON/OFFswitchto“O”(unitswitchedoff).
2. Plugthepowercableplugintoamainssocketoutlet.
3. Choosetheelectrodebasedonthetypeofmaterialandthicknessoftheworkpiecetobewelded.
4. Insert the electrode in the electrode holder.
5. Connecttheelectrodeholdercabletotheweldingsocketbasedonthepolarityrequestedbythe
typeofelectrodeused.
6. Connecttheplugofthegroundclamptotheweldingsocketonthebasisofthepolarityrequired.
7. Connecttheearthclamptotheworkpiecebeingprocessed.
DANGER!
Electric shock hazard!
Read the warnings highlighted by the following symbols in the “General prescriptions for use”.
8. SettheweldingpowersourceON/OFFswitchto“I”(unitpowered).
9. Selectthefollowingweldingmodeontheuserinterface:MMA
10.Settherequiredweldingparametervaluesontheuserinterface.
Whentheremotecontroller[RC]isconnectedandtherelativelockingscrewistightened,welding
currentcanbeadjustedusingtheremotecontroller.
Thesystemisreadytostartwelding.
REAR VIEW FRONT VIEW
(polarity to basic electrode)
RC
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6
Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
9
ENGLISH
2.5 PREPARING FOR TIG WELDING
NOTE: For the cooler to power source assembly procedure refer to the cooler instruction man-
ual.
1. SettheweldingpowersourceON/OFFswitchto“O”(unitde-energized).
2. Plugthepowercableplugintoamainssocketoutlet.
3. Connectthegashosefromtheweldinggascylindertothereargassocket.
4. Openthecylindergasvalve.
5. Choosetheelectrodebasedonthetypeofmaterialandthicknessoftheworkpiecetobewelded.
6. Insert the electrode in the TIG torch.
7. Connectthetorchplugtotheweldingsocketonthebasisofthepolarityrequiredbythetypeof
electrodeinquestion.
8. Connecttheplugofthegroundclamptotheweldingsocketonthebasisofthepolarityrequired.
9. Connectthegashosefromtheweldingtorchtothefrontgassocket.
10.ConnecttheweldingtorchconnectortotheTIGtorchsignalsconnector.
11.Connecttheearthclamptotheworkpiecebeingprocessed.
12.SettheweldingpowersourceON/OFFswitchto“I”(unitpowered).
13.Selectthefollowingweldingmodeontheuserinterface:DCTIG
14.Pressthetorchtriggerwiththetorchwellclearofanymetalparts.Thisservestoopenthegas
solenoidvalvewithoutstrikingtheweldingarc.
15.Usetheowcontrolvalvetoadjusttheowofgasasrequiredwhilethegasisowingout.
16.Settherequiredweldingparametervaluesontheuserinterface.
Whentheremotecontrolpedalisconnectedandtherelativelockingscrewistightenedtheweld-
ingcurrentwillvaryinrelationtothepressureexertedonthepedal.
Thesystemisreadytostartwelding.
REAR VIEW FRONT VIEW
(polarity for tungsten electrode)
RC
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6 Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
10
ENGLISH
3 USER INTERFACE
Cruiser 322AC/DC - Power Pulse 322AC/DC
L1
L2
L15
L16
L17
L36
L39
L40
L42
L41
L18
L19
L20
L21
L22 L23
L24
L25
L26
L27
L28
L29
L3
L4 L5
S1 S2 S3 S4
L31
L30 S5 S6
L6 L7 L8 L9 L11L10 L12 L13 L14 E1
D1 D2
L35
L34
L32
L33
L38
Cruiser 402 AC/DC - Power Pulse 402 AC/DC
L1
L2
L15
L16
L17
L37
L39
L40
L42
L41
L18
L19
L20
L21
L22 L23
L24
L25
L26
L27
L28
L29
L3
L4 L5
S1 S2 S3 S4
L31
L30 S5 S6
L6 L7 L8 L9 L11L10 L12 L13 L14 E1
D1 D2
L35
L34
L32
L33
L36 L38
CODE SYMBOL DESCRIPTION
L1 ThisLEDilluminatestoconrmthepresenceofpowerontheoutputsockets.
L2 ThisLEDilluminatestoshowananomalyintheoperatingconditions.
L3 IlluminatestoshowthatapreviouslysavedJOBhasbeenloaded.
Antwerpsesteenweg 949 9041 Gent - Oostakker
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www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6
Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
11
ENGLISH
CODE SYMBOL DESCRIPTION
L4 Illuminationshowsthatthefollowingfunctionhasbeenactivated:HIGHFREQUENCYARC
STRIKE (HF)
L5
Illuminationshowsthatthefollowingfunctionhasbeenactivated:VRD(reducedoutputvolt-
age).
Theno-loadvoltage betweenthe weldingsockets isswitchedfrom U0to Ur(seetechnical
data).
L6 Illuminatestoindicateavalueinthefollowingunitofmeasurement:AMPERES
L7
Illuminatestoshowthelastvoltageandcurrentvaluesmeasuredduringwelding.
Thevalueappearsonthefollowingdisplays:D1-D2
TheLEDswitchesoffwhenanewweldingprocedureisstarted,orwhenanyofthewelding
settingsismodied.
L8 Illuminatestoindicateavalueinthefollowingunitofmeasurement:VOLTS(V)
L9 Illuminatestoindicateavalueinthefollowingunitofmeasurement:MILLIMETERS(mm)
L10 Illuminatestoindicateavalueinthefollowingunitofmeasurement:AMPERES(A)
L11 Illuminatestoindicateavalueinthefollowingunitofmeasurement:SECONDS(s)
L12 Illuminatestoindicateavalueinthefollowingunitofmeasurement:HERTZ(Hz)
L13 Illuminatestoindicateavalueinthefollowingunitofmeasurement:KILOHERTZ(KHz)
L14 Illuminatestoindicateavalueinthefollowingunitofmeasurement:PERCENTAGE(%)
L15
WhenthisLEDilluminatesthefollowingparametercanbeset:Q-START
ACTIGmode:WhenthisLEDilluminatesthefollowingparametercanbeset:MIXAC/DC
L16
WhenthisLEDilluminatesthefollowingparametercanbeset:DYNAMICARC
ACTIGmode:WhenthisLEDilluminatesthefollowingparametercanbeset:FUSIONEXTRA
L17
WhenthisLEDilluminatesthefollowingparametercanbeset:MULTITACK
ACTIGmode:WhenthisLEDilluminatesthefollowingparametercanbeset:ACFREQUENCY
(Hz)-
L18 ACTIGmode:WhenthisLEDilluminatesthefollowingparametercanbeset:ACTIGBALANCE
L19
ACTIGmode:WhenthisLEDilluminatesthefollowingparametercanbeset:ELECTRODE
DIAMETER(mm)
ThisLEDasheswhenthesetweldingcurrentistoohighinrelationtothechosenelectrode
diameter.
L20 WhenthisLEDilluminatesthefollowingparametercanbeset:STARTINGCURRENT(%/A)
L21 WhenthisLEDilluminatesthefollowingparametercanbeset:SLOPEUP(s)
L22 WhenthisLEDilluminatesthefollowingparametercanbeset:WELDINGCURRENT(A)
L23 WhenthisLEDilluminatesthefollowingparametercanbeset:SECONDCURRENTB-LEVEL
(%)
Antwerpsesteenweg 949 9041 Gent - Oostakker
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T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6 Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
12
ENGLISH
CODE SYMBOL DESCRIPTION
L24 WhenthisLEDilluminatesthefollowingparametercanbeset:BASECURRENT(A)
L25 WhenthisLEDilluminatesthefollowingparametercanbeset:PEAKTIME(s)
L25+L26 When this LED illuminates the following parameter can be set: PULSED CURRENT
FREQUENCY(Hz/kHz)
L26 WhenthisLEDilluminatesthefollowingparametercanbeset:BASETIME(s)
L27 WhenthisLEDilluminatesthefollowingparametercanbeset:SLOPEDOWN(s)
L28 WhenthisLEDilluminatesthefollowingparametercanbeset:/STARTINGCURRENT(%/A)
L29 WhenthisLEDilluminatesthefollowingparametercanbeset:POST-GAS(s)
L30 Illuminatestosignalactivationofaconnectedremotecontrolunit,ifavailable.
L31 ThisLEDindicatesthatthecurrentreferencesettingisimposedbytheremotecontroller.
L32 Illuminationshowsthatthefollowingfunctionhasbeenactivated:2strokeprocedure.
L33 Illuminationshowsthatthefollowingfunctionhasbeenactivated:4strokeprocedure.
L34 Illuminationshowsthatthefollowingfunctionhasbeenactivated:4strokeB-levelprocedure+
highfrequencyarcstrike(HF).
L35 Illuminationshowsthatthefollowingfunctionhasbeenactivated:2strokespotprocedure(Q-
SPOT).
L36 ThisLEDilluminatestoshowthatthefollowingweldingmodeisselected:MMA
L37 This LED illuminates to show that the following welding mode is selected: GOUGING
ELECTRODE (Only on 402-502)
L38 ThisLEDilluminatestoshowthatthefollowingweldingmodeisselected:TIGDCCONTINUOUS
L39 ThisLEDilluminatestoshowthatthefollowingweldingmodeisselected:PULSEDDCTIG
L40
ThisLEDilluminatestoshowthatthefollowingweldingmodeisselected:SYNERGICPULSED
DC TIG
Whenthisison,itmeansthatthesynergicmodeisactiveandthattheoperatorcansetjustthe
weldingcurrentwhiletheotherparametersareautomaticallyregulatedbythemachine.The
synergyisoptimisedbyanglewelding.
L41 ThisLEDilluminatestoshowthatthefollowingweldingmodeisselected:TIGACCONTINUOUS
L42 ThisLEDilluminatestoshowthatthefollowingweldingmodeisselected:PULSEDACTIG
D1
Datasetting:Thedisplayshowstheacronymoftheparametertobeset.
Welding:Thedisplayshowstheeffectiveamperesvalueduringwelding.
HOLDfunction:Thedisplayshowstheaveragecurrentvaluemeasuredovertheentirewelding
period(excludingthestartingandendingramps).
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6
Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
13
ENGLISH
CODE SYMBOL DESCRIPTION
D2
Datasetting:Thedisplayshowsthevalueoftheselectedparameter.
Welding:Thedisplayshowstheeffectivevoltageduringweldingoperations.
HOLDfunction:Thedisplayshowstheaveragevoltagevaluemeasuredovertheentirewelding
period(excludingthestartingandendingramps).
S1
Pressthebuttontoselecttheparametertobeset.
Possiblechoices:Q-START-DYNAMICARC-MULTITACK
ACTIGmode:Pressthebuttontoselecttheparametertobeset.
Possiblechoices:MIXAC-EXTRAFUSION-ACFREQUENCY–ACBALANCE-ELECTRODE
DIAMETER
S2
Pressandrelease:thebuttonselectstherstlevelmenuparameters.
Holddownfor3seconds:thebuttonopensthesecondlevelmenu.Wheninthemenu,press
andreleasethebuttontoselecttheparameters.
Keepthebuttonpressedwhilepoweringonthepowersource:thebuttonopenstheSETUP
menu.
S3 Pressandrelease:thebuttonopenstheJOBsuploadmenu.
Holddownfor3seconds:thebuttonopenstheJOBssaveanddeletemenu.
S4
Pressandrelease:thebuttonenablesthedevicetoreceivetheweldingcurrentcontrolsignal
from a remote controller.
Holddownfor3seconds:thebuttonactivatesaconnectedremotecontroller,ifavailable,which
isthenusedtomanageallfunctionsoftheweldingpowersourcefromadistance.
S5 TIGDC/TIGACmode:Thisbuttonselectsthetorchtriggerprocedure.
MMAmode:PressthebuttontoshowtheselectedelectrodetypeforMMAwelding.
S6 Thisbuttonselectstheweldingmode.
E1 Datasetting:Theencodersetsthevalueoftheselectedparameter.
Welding:Theencodersetsthevalueofthefollowingparameter:WELDINGCURRENT
4 UNIT POWER-UP
SettheweldingpowersourceON/OFFswitchto“I”toswitchontheunit.
FX.XThemessageappearsonthefollowingdisplay:D2.
x.x=softwareversion
Firstpower-uporpower-upsfollowingaRESETprocedure
Theweldingpowersourcesetsupforweldingwiththefactorypre-sets.
Subsequentpower-ups
Theweldingpowersourcesetsupforweldinginthelateststableweldingcongurationthatwasactive
atthetimeofpower-off.
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6 Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
14
ENGLISH
5 RESET (LOAD FACTORY SETTINGS)
L1
L2
L15
L16
L17
L37
L39
L40
L42
L41
L18
L19
L20
L21
L22 L23
L24
L25
L26
L27
L28
L29
L3
L4 L5
S1 S2 S3 S4
L31
L30 S5 S6
L6 L7 L8 L9 L11L10 L12 L13 L14 E1
D1 D2
L35
L34
L32
L33
L36 L38
rEC PAr
A C A
B
ACTIVATION/
SELECTION ACTIVATIONEXIT
SETTING
Theresetprocedureinvolvescompleterestorationofthedefaultvalues,parametersandmemoryset-
tings set in the factory.
Theresetprocedureisusefulinthefollowingcases:
- Toomanychangesmadetotheweldingparameterssouserndsitdifculttorestoredefaults.
- Unidentiedsoftwareproblemsthatpreventtheweldingpowersourcefromfunctioningcorrectly.
PARTIAL RESET
Theresetprocedureinvolvesrestorationoftheparametervaluesandsettings,exceptthefollowing
settings:
- SettingsoftheSETUPmenu.
- SavedJOBS.
TOTAL RESET
Theresetprocedureinvolvescompleterestorationofthedefaultvalues,parametersandmemoryset-
tings set in the factory.
Allmemorylocationswillberesetandhenceallyourpersonalweldingsettingswillbelost!
A
○ SettheweldingpowersourceON/OFFswitchto“O”toswitchtheunitoff.
○Keeping both the S1 and S6 buttonspressed,setthe generatorpowersource
switchto“I”toturnontheequipment[ SIMULTANEOUS ACTIONS]
- rEC PAr: Themessageappearsonthefollowingdisplays: D1-D2.
B ○Select encoder E1 withthefollowingsetting: rEC PAr (partial) or rEC FAC (total).
Antwerpsesteenweg 949 9041 Gent - Oostakker
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T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6
Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
15
ENGLISH
C
○Exit with conrmation
- Press the S3 button.
- Waitforthememoryclearproceduretoterminate.Thisactionwillautomaticallyclosethe
menu.
○Exit without conrmation
- Press any button(except S3).
- Thisactionwillautomaticallyclosethemenu.
6 SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE)
L1
L2
L15
L16
L17
L37
L39
L40
L42
L41
L18
L19
L20
L21
L22 L23
L24
L25
L26
L27
L28
L29
L3
L4 L5
S1 S2 S3 S4
L31
L30 S5 S6
L6 L7 L8 L9 L11L10 L12 L13 L14 E1
D1 D2
L35
L34
L32
L33
L36 L38
AC
B
SEt UP
ACTIVATION/
SELECTION
EXIT
SETTING
A
○ SettheweldingpowersourceON/OFFswitchto“O”toswitchtheunitoff.
○Holding the S2 buttondown,turnthepowersourceswitchto“I”tostarttheequipment.
[ SIMULTANEAOUS ACTIONS]
- SEt UP:Themessageappearsforafewsecondsonthefollowingdisplays:D1-D2.
- Coo Aut: The messageappearsonthefollowingdisplays:D1-D2.
○Use the S2 ,buttontoscrollthroughthesettingstobemodied.
B ○Using the encoder E1 ,editthevalueoftheselectedsetting.
C
○Exit with conrmation
- Pressanybutton(except S2)forexampleS3 .
- Thisactionwillautomaticallyclosethemenu.
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6 Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
16
ENGLISH
Tab. 1 - Setup settings
ACRONYM SETTING MIN DEFAULT MAX
Coo COOLER ACTIVATION Aut Aut oFF
St.C. STARTING CURRENT %%A
F.Cu. FINAL CURRENT %%A
HF.C. HF CURRENT 20 A SYn 250 A
HF.t. HF TIME 0.5 s 2.0 s 3.0 s
PUL. TYPEOFPULSEDCURRENT SLo. FA. FA.
P.A. PILOT ARC oFF on on
E.C.C. CONTACTCOMMANDEXPANSION oFF oFF on
E.r.C. ENABLE READ CURRENT oFF on on
StS SPECIAL TORCH STROKE oFF oFF 2
F.r.C. COMMANDTYPEPEDAL 229
I.UP UP CURRENT oFF oFF oN
- Coo [COOLER ACTIVATION GROUP]
○ ON=Thecoolerisalwaysrunningwhenthepowersourceisswitchedon.Thismodeispreferable
forheavydutyandautomaticweldingprocedures.
○ OFF=Thecoolerisalwaysdisabledbecauseanair-cooledtorchisinuse.
○ AUT=Whentheunitisswitchedonthecoolerisswitchedonfor15s.Duringweldingprocedures
thecoolerrunsconstantly.Whenweldingisterminatedthecoolercontinuestorunfor90s+a
numberofsecondsequivalenttotheaveragecurrentvalueshownusingtheHOLDfunction.
Torch loading
WARNING!
Make sure the torch in use is correctly sized in relation to the welding current required and for
the available and selected cooling type. This prevents the risk of burns to which the operator is
potentially exposed, potential faults, and irreversible damage to the torch and the system.
If a torch is installed or replaced while the unit is running, the circuit of the newly installed torch
must be lled with coolant to avoid the risk of damage to the torch in the case of high voltage arc
strikes without any liquid in the circuit.
Power-up with operation of the cooler set to "ON" or "AUT" mode
○ Acheckisperformedautomaticallyofthepresenceofliquidinthecoolingcircuitandthecooler
isswitchedonfor15seconds.
○ Ifthecoolantcircuitisfull,thepowersourcesetsupinthemostrecentstableweldingcongura-
tion.
○ Ifthecoolantcircuitisnotfull,allfunctionsareinhibitedandtherewillbenooutputpowerpresent.
AL. Coo.:Themessageappearsonthefollowingdisplays: D1-D2.
 Pressanybuttontorepeatthecheckingprocedureforanadditional15seconds.
  Iftheproblempersists,rectifythecauseofthealarm.
Power-up with operation of the cooler set to "OFF"
Operation of the cooler and the cooler alarm are disabled.
Weldingisperformedwithoutliquidcoolingofthetorch.
Torch change-over with operation of the cooler set to "ON"
Press and release the torch trigger.
Antwerpsesteenweg 949 9041 Gent - Oostakker
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25/05/2018 V.2.6
Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
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ENGLISH
Thisservestostartthecoolerfor15secondstollthetorchcoolingcircuit.
- St.C. [STARTING CURRENT]
○ Thevalueofthisparametercanbesetasapercentageoftheweldingcurrentorasanabsolute
valueexpressedinAmperes.
- F.C. [FINAL CURRENT]
○ Thevalueofthisparametercanbesetasapercentageoftheweldingcurrentorasanabsolute
valueexpressedinAmperes.
- HF.C. [HF CURRENT]
○ ThisparameterestablishesthecurrentvalueduringHFdischarge.Thevalueofthisparameter
canbesetasanabsolutevalueorinSYN.
○ WithSYNsettingtheHFcurrentvalueiscalculatedautomaticallyonthebasisofthepre-setweld-
ingcurrentvalue.
Consequences of a higher value:
• Arcstrikingisfacilitated,evenonverydirtyworkpieces.
• Riskofpiercingexcessivelythingaugeworkpieces.
- HF.t. [HF TIME]
○ Thisparameterdenesthemaximumhighfrequency(HF)arcstrikeduration.
- PUL. [TYPE OF PULSED CURRENT]
○ SLo.=Thissettingenablesslowpulsedmode.Thepeaktimeandbasetimeareset.
○ FA.=Thissettingenablesfastpulsedmode.Thefrequencyandduty-cycleareset.
- P.A. [PILOT ARC]
○ Thefunctionenablestheoutputofalowcurrentbetweenthe1stand2ndtimesofthetorchtrig-
gertoshieldthemaskinadvanceandavoidtheriskofblindingashbackcausedbythewelding
current.
- C.C.E CONTACT COMMAND EXPANSION
○ ThefunctionenablestheemissionoftheARC-ONandALARMsignalsviathesignalconnectors
forautomaticapplications.
- E.r.C. [ENABLE READ CURRENT]
○ Thisfunctionallowsfortherealweldingcurrentdisplaytobeenabledordisabled.
- StS [SPECIAL TORCH STROKE]
○The parameter changes the torch trigger operating mode.
• oFF: indicates standard operation.
• 1:speciesthe4TB-levelmanagementvariant.Allowsthetransitiontothesecondarywelding
currentbypressingandholdingdowntheUPorDOWNbutton;whenthebuttonisreleased,
theprimarycurrentisrestored.WithvariantoFFselected,theUP/DOWNbuttonsaredisabled
forallprocedures.
• 2:speciesthedownslopemanagementvariant.Byreleasingthetorchtriggerduringthethird
stroke(3S)thedownslopeisstoppedandthenalcurrentisimmediatelydeliveredwithout
havingtogothroughtheentireslopetime.
- F.r.C. [COMMAND TYPE PEDAL]
○ Theparameterselectsthetypeofpedalused:
• RC02 standard pedal type
Antwerpsesteenweg 949 9041 Gent - Oostakker
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T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6 Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
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ENGLISH
• RC09specialpedaltype.Thistypeofpedalrecognisesthepressureappliedtothefootpedal
orthetorchbutton,switchingautomaticallyfrominternaladjustmenttoexternalcontrolusing
the pedal.
- I.UP [UP CURRENT]
○ WhentheparameterissettoON,themaximumvalueoftheweldingcurrentthatcanbesetwith
theUP/DOWNtorchisthecurrentsetbytheencoderinthefrontpaneloftheweldingpower
source.WhentheparameterissettoOFF,themaximumvalueoftheweldingcurrentthatcanbe
setwiththeUP/DOWNtorchisthemaximumcurrentthatcanbesuppliedbytheweldingpower
source.
7 ALARM MANAGEMENT
ThisLEDilluminatesifanincorrectoperatingconditionoccurs.
Analarmmessageappearsonthefollowingdisplay:D2.
Tab. 2 - Alarm messages
MESSAGE MEANING EVENT CHECKS
AL. HEA.
In start-up phase Appears for 2-3 seconds
Overheating alarm
Indicates tripping of the welding
powersourcethermalprotection.
Leavetheunitrunningsothatthe
overheated components cool as
rapidly as possible.
When the unit has cooled, the
welding power source will reset
automatically.
Allfunctionsdisabled.
Exceptions:
• Cooling fan.
• Cooler(ifswitchedon).
• Make sure that the power re-
quiredbytheweldingprocessis
lower than the maximum rated
poweroutput.
• Check that the operating con-
ditions are in compliance with
theweldingpower sourcedata
platespecications.
• Check for the presence of ade-
quateaircirculationaroundthe
weldingpowersource.
Phase missing alarm
Indicates the absence of a phase
inthepowersupplyline.
The message appears at the
same time as the mains protection
activationLEDswitcheson.
Allfunctionsdisabled.
Exceptions:
• Cooling fan.
• Check if the equipment power
supplylinehasallthephases.
If the problem persists:
• qualied technical personnel
are required for repair/mainte-
nancejobs.
AL. Coo.
Cooler alarm
Indicates insufcient pressure in
thetorchliquidcoolingcircuit.
Allfunctionsdisabled.
Exceptions:
• Cooling fan.
The alarm message persists on
thedisplayuntiltherstoperation
isperformedontheuserinterface.
Signalling of the alarm depends
onthefollowingsettings:
• Coo=on:thealarmissignalled
ifthe cooling unitis connected
tothepowersourceandifitis
running.
• Coo= oFF: thealarm is never
signalled,irrespectiveofthecir-
cumstances.
• Coo=Aut:thealarmissignalled
ifthe cooling unitis connected
tothepowersourceandifitis
running.
• Check that the connection to
the cooler is correct.
• Check that the "O/I" switch is
setto"I"andthatitilluminates
whenthepumpisrunning.
• Check that the cooler is lled
withcoolant.
• Check that the cooling circuit
isliquidtight, notablythetorch
hoses,thefuseandtheinternal
connections of the cooler.
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6
Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
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ENGLISH
MESSAGE MEANING EVENT CHECKS
E. 69
Software compatibility error
Indicates that the welding power
sourcehasasoftwareversionthat
isnotcompatiblewiththeremote
device connected to it (remote
controller,wirefeedunit).
Allfunctionsdisabled.
Exceptions:
• Cooling fan.
• Updatetheremotedevicesoft-
ware.
• Contactsupport
E. 04 Alarm, no-load voltage failure
Allfunctionsdisabled.
Exceptions:
• Cooling fan
• Check to ensure the welding
torchisnotrestingonthework-
piececonnectedtoground.
• Check that when the power
source is switched on there
is no short circuit between the
sockets(voltagemustbegreat-
erthan/equivalenttoUr).
If the problem persists:
• Qualied technical personnel
are required for repair/mainte-
nancejobs.
E. 05
Torch button alarm
Indicates that when the power
source was powered up a short
circuitwas detected onthe torch
triggerinput.
When the unit has cooled, the
welding power source will reset
automatically.
Allfunctionsdisabled.
Exceptions:
• Cooling fan.
• Make sure the torch trigger is
not pressed, jammed, or short
circuiting.
• Make sure the torch and torch
connector are intact.
CAn Err.
No communication alarm
Indicates the presence of prob-
lems in data communication be-
tweenthepowersourceandwire
feeder.Whentheunithascooled,
theweldingpowersourcewillre-
setautomatically.
Exitthealarmstatebyperforming
oneofthefollowingactions:
Switchthepowersourceoff.
Allfunctionsdisabled.
Exceptions:
• cooling fan.
• cooler(ifswitchedon).
• Check that the connecting cable
betweenpowersourceandwire
feederis intact andmake sure
the connectors are securely
tightened.
If the problem persists:
• qualied technical personnel
are required for repair/mainte-
nancejobs.
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T +32 (0)9 355 74 26
F +32 (0)9 355 92 01
WELD THE WORLD
Cod. 006.0001.1820
25/05/2018 V.2.6 Cruiser 322/402/502AC/DC
Power Pulse 322/402/502AC/DC
20
ENGLISH
8 MMA WELDING
8.1 TIG WELDING/GOUGING - FIRST LEVEL MENU
L1
L2
L15
L16
L17
L37
L39
L40
L42
L41
L18
L19
L20
L21
L22 L23
L24
L25
L26
L27
L28
L29
L3
L4 L5
S1 S2 S3 S4
L31
L30 S5 S6
L6 L7 L8 L9 L11L10 L12 L13 L14 E1
D1 D2
L35
L34
L32
L33
L36 L38
B A
C
80 70.0
SETTING
ACTIVATIONSELECTION
A
○Press the S6 buttontoactivatetheMMAorGOUGINGmode.
L37
L39
L40
L42
L41
S6
L36
L38
A
L 36 MMA
L 38 GOUGING
B
○Press the S2 buttontoscrollthelistofsettingstoedit.
- Theacronymrelativetothesettingtobeeditedappearsonthefollowingdisplays:D1.
- Thevaluerelativetotheselectedsettingappearsonthefollowingdisplays:D2.
C ○Using the encoder E1 ,editthevalueoftheselectedsetting.Thevalueissavedautomati-
cally.
Tab. 3 - Parameters of the 1st level menu: MMA/GOUGING mode
ACRONYM SETTING MIN DEFAULT MAX NOTES
-WELDING CURRENT
MAXIMUMCURRENTWITHREMOTECONTROLLER 10 A 80 A MAX A
MAX: Maximum
value of welding
current
Ho.S. HOT-START 0 % *SYn 100 % Only MMA
Ar.F. ARC FORCE 0 % *SYn 250 % Only MMA
Press any key (except S2)tosavethesettingandexitthemenu.
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