Ter Welding Multi 250 Instruction Manual Download

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Multi 250 - 400K - 500F - 500K -

5000FW

500MAR e Accessori

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

Edition of 30/03/2016

Multi 250 - 400K - 500F - 500K -

5000FW -

500MAR e

Accessories

Instruction Manual

lis

Summary of Contents for Multi 250

Page 1: ...400K 500F 500K 5000FW 500MAR e Accessori This manual must be completed by the CE Operating and service maual Edition of 30 03 2016 Multi 250 400K 500F 500K 5000FW 500MAR e Accessories Instruction Manual GB English ...

Page 2: ......

Page 3: ...t 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 supply before every operation Carry out the following ...

Page 4: ...EU 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 30 03 2016 IN CASE OF ANY TECHNICAL PROBLEM ASK FOR QUALIFIED SERVICE ASSISTANCE The equipment don t compiles with EN IEC 61000 3 12 The installer or the user must be sure that it can be...

Page 5: ...recautions 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 in the presence of explosive dust gases or fumes Al...

Page 6: ... 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 machine is used on domestic lines 6 STANDBY The machine...

Page 7: ...tly possible to calibrate the speed of the wire which with the use of different torches and welding wires with different diameter and con sistency 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 Parameter Function With this mode of operation the dis...

Page 8: ...ons are re covered 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 phases and should one of those fail for 20 m s machine functions stop and display will sho...

Page 9: ...ooling unit THE USER S UTILIZER MUST VERIFY THE PRESENCE AND THE CORRECT CIRCULATION TO VERIFY THE PRESENCE AND THE CORRECT CIRCULATION OF THE COOLING LIQUID COOLING DOWN Failure to control could result in damage to equipment and torches Failure to control could result in damage to equipment and torches The cooling unit unit only works when the Mig Pulsed Mig or Cooling Tig process is activated It...

Page 10: ...50A 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 Mag synergi programs N 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 puls Mig program opt opt opt opt no Optional wat...

Page 11: ... with Duo kit secondary wire feeder unit 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 synergic double pulsed Pulsed MIG Sinergyc MIG MIG PULS Sin...

Page 12: ...nual 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 cally switching the corr...

Page 13: ...n 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 Select STICK B Select MANUAL C Adjust welding current MMA CELLULOSIC Manual 10 MULTI 5000FW Wheeled base with tank compa...

Page 14: ...STICK B Select electrode type C Select electrode size 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 adjust the required value Two se...

Page 15: ...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 with the workpiece mainta...

Page 16: ...ording 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 ADJUST OR MODIFY THE WELD...

Page 17: ...in 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 can select your Mig weldi...

Page 18: ...entual 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 rele ased C 2T slope arc strikes when torch trigger is pressed and stops when released with a slope down D 4T trigger arc stri...

Page 19: ...uctance 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 From The Machine Panel Mig Mag Synergic Setting available for generators Serie K and Serie K DUO NOTE material type B refers to the wire spool type...

Page 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 arc lenght led light on...

Page 21: ...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 pressing the key SELECT once again 5 set the trigger mode 2T 4T 2T...

Page 22: ... tick 21 3 Inductance setting Mig Pulse Mode Display shows the increasing or decreasing pourcentage towards the pre set syn ergic 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 until inductance led light ...

Page 23: ...ct 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 the real voltage 5 ...

Page 24: ...iguration 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 From The Remote Wire Feeder Unit 1 press the key MODE until icon twic...

Page 25: ...d directly on the remote wire feeder unit panel 1 3 2 MMA CELLULOSIC 22 23 5 Synergi mode Setting thickness In the synergic mode it is possible to set the thickess of the material When you set the thickness all other welding parameter will be updated automatically 1 press the key SELECT until display 1 shows the message thi and the display 2 the value of thickness 2 with keys and left side adjust ...

Page 26: ...GB English Instruction Manual ...

Page 27: ...GB English Instruction Manual ...

Page 28: ...ck Blue 3 C0098AA Back Wheels 4 C0099AA Front Directional wheels 5 C0147AA Plastic Plug 6 D0138AA 90 degree Plastic Elbow 7 I0178AA Water Pump 8 I0079AA Heat exchanger Device 9 D0264AA External Water Pipe 10 D0168AA Water speed pass access Block 11 C0129AA Water Box 12 A0024AA Flow sensors A0025AA Water filter Spare Parts Multi Cooler Unit 5 6 3 4 9 10 11 12 13 7 8 2 25 ...

Page 29: ...GB English Instruction Manual ...

Page 30: ...GB English Instruction Manual ...

Page 31: ...al switch 60A S1 2 C0144AA Knob 3 C0054AA Handle block 4 C0056AA Handle block 5 B0078AA Fast socket 6 D0171AA 2 poles 7 D0202AA 5 poles 8 C0026AA Gas connector components 9 D0190AA Chain 10 C0115AA External gas bottle support 12 B0104AA Backside 14 poles socket 13 T177PCB Digtal display control PCB1 14 D0175AA Fan net Spare Parts Multi 500F 28 GB English ...

Page 32: ...GB English Instruction Manual WELDING DIAGRAM MULTI 500F 29 ...

Page 33: ...GB English Instruction Manual ...

Page 34: ...A S1 2 C0144AA Knob 3 C0257AA Flange brass components 4 D0137AA Red quick water connector 5 P0022AA Water ByPass 6 D0168AA Blue quick water connector 7 B0078AA Fast socket 8 D0171AA Air socket 9 D0172AA Air socket 10 C0026AA Gas connector components 11 D0190AA Chain 13 B0104AA Backside 14 poles socket 14 T177PCB Digtal display control PCB1 15 D0175AA Fan net Spare Parts Multi 500K 31 GB English ...

Page 35: ...ry transformer 50Hz T2 20 M0033AA Toroidal HF transformer T3 21 M0034AA output choke L1 22 T192PCB Probe filter PCB5 23 E0021AA rectifier D1 D2 D3 Spare Parts Multi 500K MULTI 500K N CODE TER CODE DESCRIPTION Rif WEL DIAGRAM 24 E0022AA Absorption PCBA PCB6 PCB7 PCB8 25 D0162AA Fan cover 26 D0161AA Fan FAN 27 D0164AA Spool Support 28 A0022AA Wire feeder 29 T188PCB Driver Board PCB4 30 A0003AA Solen...

Page 36: ...GB English Instruction Manual WELDING DIAGRAM MULTI 500K 33 GB English ...

Page 37: ...GB English Instruction Manual GB English ...

Page 38: ...1 2 C0144AA Knob 4 D0171AA 2 poles 5 D0172AA 5 poles 6 C0026AA Gas connector components 7 B0078AA Fast socket 21 B0104AA Backside 14 poles socket 25 T177PCB Digtal display control PCB1 Spare Parts Multi 5000FW N CODE Multi 250 400K 500F 500K 5000FW 500MAR e Accessori Instruction Manual GB English ...

Page 39: ...are Parts Multi 5000FW N CODE DESCRIPTION Rif WEL DIAGRAM 18 M0036AA Toroidal HF transformer T3 19 T194 T195PCB 400K Driver Board PCB4 20 M0021AA auxillary transformer 50Hz T1 21 M0042AA auxillary transformer 50Hz T2 22 B0104AA Backside 14 poles socket 23 D0190AA Chain 24 C0115AA External gas bottle support Spare Parts Multi 5000FWF Multi 5000FW 23 24 21 Multi 250 400K 500F 500K 5000FW 500MAR e Ac...

Page 40: ...37 WELDING DIAGRAM MULTI 5000FW5 Multi 250 400K 500F 500K 5000FW 500MAR e Accessori Instruction Manual GB English ...

Page 41: ...38 Multi 250 400K 500F 500K 5000FW 500MAR e Accessori Instruction Manual GB English ...

Page 42: ...LTI 400KW 1 25 2 7 6 5 4 3 7 21 N CODE DESCRIPTION Rif WEL DIAGRAM 1 D0165AA Universal switch 32A S1 2 C0144AA Knob 3 C0257AA Euro connector 4 D0171AA 2 poles 5 D0172AA 5 poles 6 C0026AA Gas connector components 7 B0078AA Fast socket 21 B0104AA Backside 14 poles socket 25 T177PCB Digtal display control PCB1 Spare Parts Multi 400K 35 GB English ...

Page 43: ...CB Auxiliary board PCB3 15 T196PCB EMC board PCB10 T192PCB Probe Filter PCB5 Spare Parts Multi 400K N CODE DESCRIPTION Rif WEL DIAGRAM 16 A0003AA Solenoid 18 M0036AA Toroidal HF transformer T3 19 T194 T195PCB 400K Driver Board PCB4 20 M0021AA auxillary transformer 50Hz T1 21 M0042AA auxillary transformer 50Hz T2 22 B0104AA Backside 14 poles socket 23 D0190AA Chain 24 C0115AA External gas bottle su...

Page 44: ...GB English Instruction Manual WELDING DIAGRAM MULTI 400K 37 ...

Page 45: ...GB English Instruction Manual ...

Page 46: ... WEL DIAGRAM 1 D0165AA Universal switch 32A S1 2 C0144AA Knob 3 C0257AA Flange brass components 4 D0171AA 2 pole connector 5 D0172AA 3 pole connector 6 C0026AA Gas connector components 7 B0078AA Fast socket 21 B0104AA Backside 14 poles socket 25 T177PCB Digtal display control PCB1 Spare Parts Multi 250K 39 ...

Page 47: ...0312AA Plastic internal module 12 T173PCB Wire control PCB PCB9 13 T178PCB Contor PCB PCB2 16 T182PCB EMC board PCB7 Spare Parts Multi 250K N CODE DESCRIPTION Rif WEL DIAGRAM 16 A0003AA Solenoid 19 T198PCB 250K Driver Board PCB4 23 D0190AA Chain 24 C0115AA External gas bottle support T192PCB Probe Filter PCB5 T200PCB Protect Board Spare Parts Multi 250K 40 ...

Page 48: ...GB English Instruction Manual WELDING DIAGRAM MULTI 250K 41 ...

Page 49: ...GB English Instruction Manual ...

Page 50: ...nter in the thecnical parameter mode To enter in the thecnical parameter mode by press 3 seconds the SELECT SW4 button The double pulse frequency can be set from 0 5Hz to 4 0Hz The Balance can be set from 5 to 90 This parameter is the the percentage of pulse to the level of low current Th level is adjustable from 20 to 90 and represents the percentage of the current value lower than the current va...

Page 51: ... 3 seconds the SELECT SW6 button The double pulse frequency can be set from 0 5Hz to 4 0Hz The Balance can be set from 5 to 90 This parameter is the the percentage of pulse to the level of low current Th level is adjustable from 20 to 90 and represents the percentage of the current value lower than the current value high TWIN UP FUNCTION UP This function is only present in some pulse programs This...

Page 52: ...ER DRIVING ALARM CONTACT SERVICE CENTER 24 HAL HALL SENSOR ALARM CONTACT SERVICE CENTER 25 CALIBRATION ALARM CONTACT SERVICE CENTER 30 c THEMPERATURE ALARM WAIT COOLING CONTACT SERVICE CENTER 33 h2o WATER FLUX ALARM CHECK WATER ON THE COOLING UNIT CONTACT SERVICE CENTER 40 ENC ENCODER ALARM CONTACT SERVICE CENTER 41 brA BREAK MOTOR OF FEEDER ALARM CONTACT SERVICE CENTER 42 MOT SPEED MOTOR ALARM CO...

Page 53: ...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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