Ter Welding Multi 250K Instruction Manual Download Page 1

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Multi 250 - 400K - 500F- 500K - 500 MAR e Accessories

This manual must be completed by the “CE Operating and service maual”

Edition of 29/05/2013

Instruction Manual

Multi 250 - 400K - 500F - 500K - 500 MAR e Accessories

Summary of Contents for Multi 250K

Page 1: ...250 400K 500F 500K 500 MAR e Accessories This manual must be completed by the CE Operating and service maual Edition of 29 05 2013 Instruction Manual GB English Multi 250 400K 500F 500K 500 MAR e Accessories ...

Page 2: ... manual In the interest of our customers we suggest any maintenance or repair of the equipment is made by qualified 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 supp...

Page 3: ... the harmonized standard 2006 95 CE LDV 2004 108 CE EMC 2002 95 RoHs and with the instructions contained in the harmonized standard if applicable EN 60974 1 EN 60974 2 EN 60974 3 EN 60974 5 EN 60974 7 EN 60974 10 EN 60974 12 Maurizio Terzo Direttor Generale Date 31 01 2012 IN CASE OF ANYTECHNICAL PROBLEM ASK FOR QUALIFIED SERVICE ASSISTANCE The equipment don t compiles with EN IEC 61000 3 12 The i...

Page 4: ...nd said limit users must therefore implement all precautions required by law PACE MAKER The magnetic fields created by high currents may affect 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 i...

Page 5: ...the welding time duty cycle is con cerned when the demanded current is highter than the available one 5 2 PLC display When the PLC inhibits the welding process the current supply is breaked immediately and the front panel shows the PLC timer count down When the timer arrives to 0 the welding job can restart Please refer to the plots in order to avoid unexpected welding interruptions when the machi...

Page 6: ...libration Function With this process it is perfectly possible to calibrate the speed of the wire which with the use of different torches and welding wires with different diameter and consistency may increase or decrease the drag The procedure is as follows Press the torch switch until the flashlight shows INC within 3 second press 3 times switch sw4 then press again the torch switch Welding Parame...

Page 7: ...o allow a correct ventilation when thermal conditions are recovered normal operations are again possible In case current exceeds the mentioned limits current peaks machine functions stop and display shows the detected current peak Reset the machine by switch ing the main ON OFF knob The tri phase version detects even the right presence of the three current phas es and should one of those fail for ...

Page 8: ...ine switching the main knob ON OFF Long unactivity 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 un...

Page 9: ...20A 500A 640A 640A 640A Short circuit limit 480A 850A 1050A 1050A 1050A Protection class IP21S IP21S IP21S IP21S IP23 Insulating class H H H H H Stick synergi programs N 19 19 19 19 pulsexpopt Tig synergi programs N 18 18 18 18 pulsexpopt Mig MagsynergiprogramsN 18 18 18 18 pulsexpopt PulsedMigsynergiprogramsN 5 5 5 5 pulsexpopt Pulsed Mig Double Pulsation ok ok ok ok pulsexpopt Up grade 8 16 32 p...

Page 10: ...ped with trolley and cooling unit Generators K Serie with Duo kit secondary wire feeder unit 11 2 Multi 400K DUO It can be equipped with trolley and cooling unit The DUO configuration double torch provides double job programs on the main generator you can select between MMA manual or synergic TIG manual or synergic PULSED TIG manual or synergic MIG MAG manual or synergic PULSED MIG synergic and sy...

Page 11: ...can select between MMA manual or synergic TIG manual or synergic PULSED TIG manual or synergic while from remote wire feeder unit MIG MAG synergic PULSED MIG synergic PULSED MIG synergic double pulsed MIG MAG manual MMA Every welding job can work with specific different programs set from the generator main panel Job transfer from main generator to wire feeder unit or viceversa is released automati...

Page 12: ...h clamp to the right main generator polari ties the electrode holder can be connected even to the wire feeder unit in that case B and C setting steps are inhibited on the wire feeder panel you can simply adjust the welding current and arc dynamic see wire feeder setting A Select STICK B Select MANUAL C Adjust welding current and weld A Select STICK B Select M ANU AL C Adjust welding current A Sele...

Page 13: ...djusting knob A Select STICK B Select electrode type C Select electrode size 14 2 HOT START MMA Mode Synergic In synergic MMA mode the value is already set according to the choosed electrode The parameter can be changed anyway adjustments are diplayed in pourcentage towards the original value push the 2nd level key until HS icon light on the led will blink for two seconds and during this time adju...

Page 14: ...on the rear panel market with tig release the gas flow at 5 7 lt min The MULTI generators provide tig torch arc strike by using the Lift Arc method push the torch trigger slow down the torch until the ceramic nozzle touch the workpiece in this phase held the torch and avoid any contact between tungsten and workpiece keeping the nozzle in contact turn the torch until the tungsten enters in contact ...

Page 15: ...ll parameters change according to the choosed program and or current level PRE GAS fix at 0 1 sec SLOPE UP slope up synergic depending on slope down CURRENT 1 synergic CURRENT 3 synergic SLOPE DOWN slope down synergic POST GAS synergic PULSATION synergic PULSATION BAL synergic TIMER variable setting by the 2nd level key MAX PULS PEAK synergic MIN PULS PEAK synergic GENERALLY USER DOESN T NEED TO A...

Page 16: ...rigger and press it again wire drives now into the torch at approx 10 mt min until trigger remain pressed f shielding gas hose is fitted to the back panel of the machine gas nipple marked with MIG Adjust the flow rate between 16 22 lt min depending on the welding task g connect the earth clamp plug to the negative polarity This procedure is valid even for the LPM remote wire feeder unit Now you ca...

Page 17: ... signals gas hose and eventual hoses for the torch cooling 19 6 Wire Speed Setting And Voltage Mig Mag Manual 19 4 Trigger Select Mig Mag Manual A TIMER it activates the spot function The spot arc remains on during the set time B 2T trigger arc strikes when torch trigger is pressed and stops when released C 2T slope arc strikes when torch trigger is pressed and stops when released with a slope dow...

Page 18: ...the keys and set the inductance The display 3 return to the previous value 1 second after the last key touch or pressing the key SELECT once again 5 set the trigger mode 2T 4T 2T slope 4T slope the slope values are al ready pre set 1 2 3 4 4 5 20 MIG MAG synergic 20 1 Setting FromThe Machine Panel Mig Mag Synergic Setting available for generators Serie K and Serie K DUO NOTE material type B refers...

Page 19: ... B adjust inductance 20 3 ARC setting Mig Mag Synergic The main knob allows arc setting between 20 short and 20 long The 0 value correspond than to the pre set synergic value In the same way you can adjust POST GAS TIMER CRATER FILLER and TRIGGER mode 20 4 Setting from the Remote Wire Feeder Unit Mig Mag Synergic First of all set the MIG MAG synergic mode on the generator main panel A press until ...

Page 20: ...adjusted from 20 up to 20 During this setting the icon Vreal is off while icon arc lenght is on 1 3 4 20 5 Inductance Setting Mig Mag Synergic 1 press the key SELECT until inductance icon 2 is on 3 the display shows the inductance value 4 using the keys and set the inductance The display 3 return to the previous value 1 second after the last key touch or press ing the key SELECT once again 5 set t...

Page 21: ...el or the basic material tick 21 3 Inductance setting Mig Pulse Mode Display shows the increasing or decreasing pourcentage towards the pre set synergic value 21 4 Arc setting Mig Pulse Mode The main knob allows arc setting between 20 short and 20 long The 0 value correspond than to the pre set synergic value In the same way you can adjust POST GAS TIMER CRATER FILLER and TRIGGER mode A press unti...

Page 22: ...eeder unit A select MIG PULSE B select material type C select wire size 1 3 4 Now approach the remote wire feeder unit and set as follow 1 press the key MODE until icon puls light on 2 with keys and left side adjust the welding current 3 display shows the set current when icon Iset light on real job welding current with Ireal icon on 4 display shows the pre set arc lenght and during welding job th...

Page 23: ...et NOTE with the DUO configuration wire spool inside the machine and another one inside the remote wire feeder double torch you can set two independent welding jobs Process and programs are automatically released pressing the respective torch trigger or any one key on the wire feeder unit or generator main panel 1 2 3 4 4 5 23 3 Mig Double Pulse Setting FromThe RemoteWire Feeder Unit 1 press the k...

Page 24: ...mote Wire Feeder Unit 1 press the key MODE until icon MMA stick light on 2 with keys and left side adjust the current value 3 NOTE setting of any synergic program is made always from front machine main panel while adjustments can be performed directly on the remote wire feeder unit panel 1 3 2 MMA CELLULOSIC 22 ...

Page 25: ... Bottom Button Sets the current or the voltage in MIG manual Left Button Trims Job Amps down to 20 Left Button Adjust the arc length in synergic or the wire speed in MIG manual The digitalTorch has two operational modes SET and JOBS To switch from on mode to another Push the Left and Bottom together In JOB mode any adjustment can be done from the front panel and is stored inside the current JOB MU...

Page 26: ...GB English Instruction Manual Multi 250 400K 500F 500K 500 MAR e Accessories ...

Page 27: ...GB English Instruction Manual Multi 250 400K 500F 500K 500 MAR e Accessories ...

Page 28: ...0220 12 00Back Wheels 4 37 160320 11 00Front Directional wheels 5 24 031200 13 A0Plastic Plug 6 24 032200 07 A090 degree Plastic Elbow 7 37 310000 01 00Water Pump 8 37 340000 01 00Heat exchanger Device 9 38 107080 01 00External Water Pipe 10 40 160910 03 00Water speed pass access Block 11 37 320000 01 00water Box 12 06 030001 02 00Flow sensors 14 40 160910 04 00Water speed pass access Block Spare ...

Page 29: ...GB English Instruction Manual Multi 250 400K 500F 500K 500 MAR e Accessories ...

Page 30: ...GB English Instruction Manual Multi 250 400K 500F 500K 500 MAR e Accessories ...

Page 31: ... Handle block 4 22 031001 02 A0C0056AA Handle block 5 40 160710 01 00B0078AA Fast socket 6 40 140120 01 00D0171AA Air socket 7 40 140120 02 00D0172AA Air socket 8 24 031000 01 A0C0026AA Gas connector components 9 37 220100 02 00D0190AA Chain 10 25 020102 58 A0C0115AA External gas bottle support 11 39 106309 01 A0 Program input serial port 12 40 141010 04 00B0104AA Backside 14 poles socket 13 T177P...

Page 32: ...GB English Instruction Manual Multi 250 400K 500F 500K 500 MAR e Accessories WELDING DIAGRAM MULTI 500F 29 ...

Page 33: ...GB English Instruction Manual Multi 250 400K 500F 500K 500 MAR e Accessories ...

Page 34: ...lange brass components 4 40 160910 06 00 D0167AA Male red quick water connector 5 38 103060 03 00 P0022AA Water ByPass 6 40 160910 05 00 D0168AA Male Blue quick water connector 7 40 160710 01 00 B0078AA Fast socket 8 40 140120 01 00 D0171AA Air socket 9 40 140120 02 00 D0172AA Air socket 10 24 031000 01 A0 C0026AA Gas connector components 11 37 220100 02 00 D0190AA Chain 13 40 141010 04 00 B0104AA...

Page 35: ...ransformer T3 21 03 020100 15 00 M0034AA output choke L1 22 T192PCB T192PCB Probe filter PCB5 23 04 010300 22 00 E0021AA rectifier D1 D2 D3 Spare Parts Multi 500K MULTI 500K N CODE TER CODE DESCRIPTION Rif WEL DIAGRAM 24 51 PH 33 E RL E0022AA Absorption PCBA PCB6 PCB7 PCB8 25 23 020602 01 A0 D0162AA Fan cover 26 37 120321 01 00 D0161AA Fan FAN 27 37 221100 02 00 D0164AA Spool Support 28 37 210433 ...

Page 36: ...GB English Instruction Manual Multi 250 400K 500F 500K 500 MAR e Accessories WELDING DIAGRAM MULTI 500K 33 ...

Page 37: ...GB English Instruction Manual Multi 250 400K 500F 500K 500 MAR e Accessories ...

Page 38: ...EL DIAGRAM 1 07 020000 18 00 D0165AA Universal switch 32A S1 2 37 231410 05 01 C0144AA Knob 3 40 180000 06 00 C0257AA Euro connector 4 40 140120 01 00 Air socket 5 40 140120 02 00 D0172AA Air socket 6 24 031000 01 A0 C0026AA Gas connector components 7 40 160710 01 00 B0078AA Fast socket 21 40 141010 04 00 B0104AA Backside 14 poles socket 25 T177PCB T177PCB Digtal display control PCB1 Spare Parts M...

Page 39: ...xiliary board PCB3 15 T196PCB T196PCB EMC board PCB10 T192PCB T192PCB Probe Filter PCB5 Spare Parts Multi 400K N CODE TER CODE DESCRIPTION Rif WEL DIAGRAM 16 37 140110 02 00 A0003AA Solenoid 17 03 020200 20 00 Output choke 18 03 010303 11 00 M0036AA Toroidal HF transformer T3 19 T194 T195PCB T194 T195PCB 400K Driver Board PCB4 20 03 010300 11 00 M0021AA auxillary transformer 50Hz T1 21 03 010500 4...

Page 40: ...GB English Instruction Manual Multi 250 400K 500F 500K 500 MAR e Accessories WELDING DIAGRAM MULTI 400K 37 ...

Page 41: ...GB English Instruction Manual Multi 250 400K 500F 500K 500 MAR e Accessories ...

Page 42: ...niversal switch 32A S1 2 37 231410 05 01 C0144AA Knob 3 40 180000 06 00 C0257AA Flange brass components 4 40 140120 01 00 D0171AA 2 pole connector 5 40 140120 02 00 D0172AA 3 pole connector 6 24 031000 01 A0 C0026AA Gas connector components 7 40 160710 01 00 B0078AA Fast socket 21 40 141010 04 00 B0104AA Backside 14 poles socket 25 T177PCB T177PCB Digtal display control PCB1 Spare Parts Multi 250K...

Page 43: ...100 01 00 Plastic internal module 12 T173PCB T173PCB Wire control PCB PCB9 13 T178PCB T178PCB Contor PCB PCB2 16 T182PCB T182PCB EMC board PCB7 Spare Parts Multi 250K N CODE TER CODE DESCRIPTION Rif WEL DIAGRAM 16 37 140110 02 00 A0003AA Solenoid 19 T198PCB T198PCB 250K Driver Board PCB4 23 37 220100 02 00 D0190AA Chain 24 25 020102 58 A0 C0115AA External gas bottle support 03 010303 21 00 Toroida...

Page 44: ...GB English Instruction Manual Multi 250 400K 500F 500K 500 MAR e Accessories WELDING DIAGRAM MULTI 250K 41 ...

Page 45: ...GB English Instruction Manual Multi 250 400K 500F 500K 500 MAR e Accessories ...

Page 46: ...Ter srl Via Giacomo Leopardi 13 36030 Caldogno VI ITALY Ph 39 0444 586440 Fax 39 0444 905764 e mail info terwelding com ...

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