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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

Содержание Cruiser 322AC/DC

Страница 1: ...6 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 info welda be www welda be T 32 0 9 355 74 26 F 32 0 9 355...

Страница 2: ...ORLD 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 info welda be www welda be T 32 0 9 355 74 26 F 32 0 9...

Страница 3: ...PECIAL 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...

Страница 4: ...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 INFO...

Страница 5: ...h the complementary parameters base current and duty cycle makes it possible to weld in slow and fast pulsed mode Thanks to its modular configuration the power source can be configured for MIG MAG wel...

Страница 6: ...rs 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 Conne...

Страница 7: ...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...

Страница 8: ...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...

Страница 9: ...quired 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...

Страница 10: ...2 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 L11 L10 L12L13L14 E1 D1 D2 L35 L34 L3...

Страница 11: ...ates 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 follow...

Страница 12: ...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...

Страница 13: ...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 seco...

Страница 14: ...event 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 SETU...

Страница 15: ...2L13L14 E1 D1 D2 L35 L34 L32 L33 L36L38 A C 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 powe...

Страница 16: ...vailable 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 insta...

Страница 17: ...y 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...

Страница 18: ...ut Check that the operating con ditions are in compliance with the welding power source data plate specifications Check for the presence of ade quate air circulation around the welding power source Ph...

Страница 19: ...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 functio...

Страница 20: ...croll 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...

Страница 21: ...Difficulty of activation Less starting splatter Reduction in the activation area ARC FORCE This parameter helps to avoid electrode sticking during welding It is set as a percentage referred to the va...

Страница 22: ...o matically allows the optimum welding parameters to be set VRD This parameter reduces the potential across the welding sockets when welding is not in progress The arc strike procedure is as follows T...

Страница 23: ...following displays D1 The value relative to the selected setting appears on the following displays D2 B Using the encoder E1 edit the value of the selected setting The value is saved automati cally T...

Страница 24: ...L41 S6 L36 L38 A L 38 TIG DC CONTINUOUS L 39 TIG DC PULSED L 40 SYNERGIC PULSED DC TIG L 41 AC TIG L 42 TIG DC PULSED B Press the S2 button to scroll the list of settings to edit The acronym relative...

Страница 25: ...EFAULT MAX USEFUL ADVICE Pr G PRE GAS TIME 0 0 s 0 1 s 10 0 s Recommended value 0 3s St C L 20 STARTING CURRENT 5 A 50 A MAX A MAX Maximum value of welding current Recommended value 30 or 15 A 2 50 20...

Страница 26: ...damaging it Particularly useful when welding thin sheets SLOPE UP Time during which the current changes from the starting value to the welding value by means of a slope This setting is used to avoid d...

Страница 27: ...crease of heat affected zone DOWN SLOPE Time during which the current changes from the welding value to the end value by means of a slope Prevents the formation of craters in the process of turning of...

Страница 28: ...42 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 L11 L10 L12L13L14 E1 D1 D2 L35 L34 L32 L33 L36L38 A B HF on SETTING 3 sec ACTIVATION SELECTION A H...

Страница 29: ...STROKE SPOT Only with HF ON HF HF ARC STRIKE ENABLE oFF on on Sl u MINIMUM PEDAL CURRENT 1 5 90 Only with the PEDAL AC WAVEFORM This parameter allows selection of the required AC waveform Tab 10 Type...

Страница 30: ...When the parameter is set to OFF the operating mode of the Q SPOT is standard HF ARC START This parameter enables the arc strike in the TIG welding procedure by means of a high frequency HF current d...

Страница 31: ...tungsten electrode on the ignition point so that there is a distance of about 2 3mm between the electrode and the workpiece 2 Touch the piece with the electrode and press the torch button according to...

Страница 32: ...AX NOTES q St Q START 0 1 s oFF 10 0 s See Table 12 d Ar DYNAMIC ARC 1 oFF 50 See Table 13 not with SYNERGIC PULSED TIG M tA MULTI TACK 0 5Hz oFF 6 0Hz See Table 14 not with SYNERGIC PULSED TIG Press...

Страница 33: ...area Minor oxidation of the piece and therefore lower post weld re work costs Better control of first application in gaps useful for pipe fitters and installers Ease of welding even for pieces which...

Страница 34: ...sperse the beat between a trigger and another By adjusting the MultiTack frequency the weld penetration speed of execution and in particular the control of the heat input can be optimised as well as a...

Страница 35: ...5 Special functions in TIG AC mode ACRONYM SETTING MIN DEFAULT MAX NOTES M AC MIX AC 10 oFF 80 E Fu FUSIONE EXTRA 0 1 oFF 80 F AC AC INVERSION FREQUENCY 20 Hz 65 Hz 200 Hz bAL AC BALANCE 10 0 10 d EL...

Страница 36: ...ect to zero It is therefore possible to create a penetrating and precise weld pool which will allow for very thin gauge sheets to be welded using an electrode tip comparable to that of an electrode fo...

Страница 37: ...to use low frequencies for the welding of relatively large thicknesses or for filling passes in multipass bevels Conversely in increasing the inversion fre quency value the arc size tends to decrease...

Страница 38: ...case the percentage of the positive wave is greater than the negative one BALANCE represents the curve of the current with a negative value AC balance more penetration in which it can be seen that th...

Страница 39: ...of certain procedures depends on whether or not certain parameters or functions of the unit are enabled or set in the associated menus The table shows the settings to be made to enable each procedure...

Страница 40: ...nd keep the torch trigger pressed Slowly lift the torch to strike the arc The welding current reaches the pre set value by way of an up slope time if programmed Release 2T the trigger to start the wel...

Страница 41: ...URRENT WELDING CURRENT FINAL CURRENT HF 4 STROKE LIFT Touch the workpiece with the torch electrode Press 1T and keep the torch trigger pressed Slowly lift the torch to strike the arc The arc strikes t...

Страница 42: ...2T the torch trigger The welding current reaches the pre set value by way of an up slope time if programmed Press 3T the trigger and keep it pressed to start the weld completion procedure The current...

Страница 43: ...ITION C C CURRENT 2nd TIME RAMP DOWN POST GAS PRIMARY CURRENT UP 3rd TIME SLOPE FINAL CURRENT 4th TIME CURRENT SECOND PRESS AND RELEASE STARTING CURRENT 4 STROKE B LEVEL Bring the torch up to the work...

Страница 44: ...ish the arc Gas delivery continues for the time set in the post gas parameter FINAL CURRENT 1st TIME 2nd TIME RAMP DOWN POST GAS PRE GAS PRIMARY CURRENT UP 3rd TIME SLOPE 4th TIME HF IGNITION CURRENT...

Страница 45: ...LDING TIME C Using the encoder E1 edit the value of the selected setting The value is saved automati cally Press any key except S2 to save the setting and exit the menu Tab 17 Parameters of the 2nd le...

Страница 46: ...act with the piece It is recommended that the spot welding position is researched an electrode that contacts the workpiece for thin layers less than 1 5mm while for greater thicknesses without making...

Страница 47: ...rrent reaches the pre set value by way of an up slope time if programmed The welding procedure continues at the pre set current for the time set with the spot time pa rameter The current reaches the e...

Страница 48: ...current reaches the end current value in the time set in the down slope time parameter The arc is extinguished Gas delivery continues for the time set in the post gas parameter Touch the workpiece wit...

Страница 49: ...TIME 1 PULSED CURRENT FREQUENCY 6 6 6 6 6 6 6 6 1 BASE TIME 5 5 5 5 1 DOWN SLOPE 1 END CURRENT 1 POST GAS TIME 2 TYPE OF ELECTRODE 2nd VRD 2 LONG ARC VOLT AGE 2nd SPOT WELDING TIME 2nd HF ARC START 2N...

Страница 50: ...CURRENT B LEVEL 1 BASE CURRENT 1 PEAK TIME 1 PULSED CURRENT FREQUENCY 6 6 6 6 1 BASE TIME 5 5 5 5 1 DOWN SLOPE 1 FINAL CURRENT 1 POST GAS TIME 2 ELECTRODE TYPE 2 VRD 2 LONG ARC VOLTAGE 2 SPOT TIG TIME...

Страница 51: ...24 L25 L26 L27 L28 L29 L3 L4 L5 S1 S2 S3 S4 L31 L30 S5 S6 L6 L7 L8 L9 L11 L10 L12L13L14 E1 D1 D2 L35 L34 L32 L33 L36L38 A B D C SA job SELECTION 3 sec ACTIVATION CONFIRM BACKUP A Hold down the S3 butt...

Страница 52: ...the JOB save delete menu SA Job The message appears on the following displays D1 D2 B Use the encoder E1 to select the following setting Er Job The message appears only if there are saved JOBS on the...

Страница 53: ...JOB and exit from the menu J xx The message appears for a few seconds on the following displays D1 The LED illuminates To quit the currently loaded JOB change any setting on the power source user int...

Страница 54: ...bility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment is connected only to a supply with maximum permis sibl...

Страница 55: ...only to a supply with maximum permis sible system impedance less than or equal to 64 m Dimensions L x D x H 690 x 290 x 450 mm Weight 55 5 kg Insulation class H Protection rating IP23 Cooling AF Air...

Страница 56: ...urrent and voltage adjustment range 10 A 20 4 V 500 A 40 0 V 5 A 10 2 V 500 A 30 0 V 20 A 15 0 V 500 A 39 0 V Welding current Working voltage 30 40 C 500 A 40 0 V 500 A 30 0 V 500 A 39 0 V 60 40 C 370...

Страница 57: ...4 3 5 1 2 JP1 CN8 JP5 JP7 5V TX2 RS232 TX1 RS232 RX2 RS232 RX1 RS232 GND GND DIG_IN_1 DIG_IN_2 DIG_IN_3 DIG_OUT_1 DIG_OUT_2 A RS485 1 2 1 2 5V REM OK FAN 5V REM GND REM 34V REM GND REM GND REM CAN L...

Страница 58: ...JP2 FLAT 34VIE CON CONT I INV AL IN SIGNAL 1 19 20 21 EV TIG OK GRUPPO SIGNAL 2 18 16 17 5V PULS UP ALARM CU SIGNAL 3 13 12 14 GND PULS DOWN 10 9 11 RIC PED GND 15V PULS TORCIA 7 6 8 5 15V SIGNAL 4 E...

Страница 59: ...0 7 9 8 JP7 33VAC 2 230VAC 1 33VAC 1 230VAC 2 JP3 1 2 4 3 4 5 6 GND REM GND REM CAN H JP14 2 1 2 1 JP7 3 4 1 5 2 GND ISO AL CU EARTH 400VAC 1 400VAC 2 YELLOW GREEN 050 XXXX 0147 J4 JP1 1 J3 J2 3 2 022...

Страница 60: ...5 2 1 3 4 2 4 3 1 2 JP1 JP2 4 24VAC 1 24VAC 2 24VAC 2 5V REM GND REM GND REM 34V REM 15V 15V 15V 15V 24VAC 1 1 3 2 4 1 2 4 4 3 3 1 2 GND GND 5 6 22 I HALL JP5 5V TX2 RS232 1 2 GND TX1 RS232 RX2 RS232...

Страница 61: ...S485 1 2 8 8 6 5 7 2 3 1 4 JP5 24V ISO 48VAC 1 CAN L 34V REM CAN H 48VAC 2 GND REM GND ISO 7 6 5 3 2 4 1 P UP GND_ISO GND_ISO RIF EXT N C 1 20 17 18 19 14 15 16 12 11 9 10 13 JP12 10V_ISO N C 2 PT CON...

Страница 62: ...RLD Cod 006 0001 1820 25 05 2018 V 2 6 Cruiser 322 402 502AC DC Power Pulse 322 402 502AC DC 62 ENGLISH Antwerpsesteenweg 949 9041 Gent Oostakker info welda be www welda be T 32 0 9 355 74 26 F 32 0 9...

Страница 63: ...ND ISO GND 24V ISO REMOTE 1 022 0002 0240 022 0002 0248 022 0002 0237 N C 2 2 JP25 8 6 7 1 24V ISO GND ISO CAN H JP23 1 2 JP24 1 2 RIF EXT 1 4 3 2 7 8 5 6 P UP GND_ISO GND_ISO N C 1 15 JP21 11 10 9 14...

Страница 64: ...2 2 1 1 6 4 5 022 0002 0238 2 3 1 J1 050 XXXX 0053 022 0002 0240 JP27 COM CU GND_ISO AL CU COM RELE 4 3 2 1 4 3 JP28 13 JP18 6 1 2 3 4 5 230VAC 1 48VAC 2 48VAC 1 7 8 9 10 12 11 230VAC 2 18VAC 2 24VAC...

Страница 65: ...V REM 48VAC 2 48VAC 1 CAN L 2 2 1 1 POWER_PULSE_VERSION RS232 COM 1 1 5 6 9 B H J K L T G S R E F N P D C A M PANEL_DIG_OUT_1 PANEL_DIG_OUT_2 PANEL_DIG_OUT_3 34V REM GND CAN A RS485 B RS485 48VAC 1 48...

Страница 66: ...INV GND 15V 15V JP26 3 1 2 1 2 4 JP17 CANH GND REM CANL 34V REM 5V REM GND REM 1 2 1 5 4 6 2 3 JP9 TERM FAN VOUT GND RELE POT RIC MACCHINA POT JP12 3 2 1 4 1 5 3 2 4 I HALL 15V AL IN 15V RID MOD 12V G...

Страница 67: ...0 7 9 8 AL CU 3 6 5 4 2 1 3 N C JP1 JP2 JP6 JP4 3 2 1 4 1 4 2 COM N O 4 3 1 2 3 4 1 JP5 17 JP6 11 10 9 12 14 13 15 16 21 19 18 20 22 1 1 3 4 2 JP3 3 2 4 JP7 1 3 2 4 JP8 1 2 3 JP10 FLAT 34VIE 17 17 050...

Страница 68: ...od 021 0004 1001 13 5 TORCH CONNECTOR front panel cod 021 0004 3360 Torch Up Down Torch 13 6 REMOTE CONTROL CONNECTOR back panel cod 021 0004 0602 Torch with Potentiometer Pot 2Kohm 10Kohm REMOTE CONT...

Страница 69: ...7 82 74 75 72 71 68 46 45 66 7 65 64 6 24 23 34 35 37 36 43 44 41 80 30 42 81 67 38 40 48 63 62 59 60 61 13 49 51 54 53 21 22 18 32 20 19 29 4 14 78 15 73 28 17 16 39 33 25 84 50 52 57 85 58 31 ENGLIS...

Страница 70: ...011 0000 0901 UPPER COVER 39 050 0001 0119 CAPACITOR BOARD 40 050 0001 0147 LINE FILTER BOARD 41 041 0006 0006 TOROIDAL TRANSFORMER 42 011 0013 0044 BOARD SUPPORT PLATE N CODE DESCRIPTION 43 011 0013...

Страница 71: ...16 18 19 20 25 23 24 78 77 76 75 74 71 70 69 68 67 66 46 45 47 7 41 44 35 31 32 33 28 27 30 28 17 73 63 62 72 43 79 34 26 44 60 59 58 55 53 52 51 13 49 48 57 56 54 50 21 22 80 82 83 84 85 61 86 42 6 8...

Страница 72: ...E 35 050 0003 0055 BUS BOARD 36 050 0002 0052 SUPPLIES BOARD 37 050 0003 0027 HF BOARD N CODE DESCRIPTION 38 011 0000 0901 UPPER COVER 39 031 1005 0228 CAPACITOR 40 050 0002 0053 LINE FILTER BOARD 41...

Страница 73: ...FUSE 87 045 0006 0104 HF COPPER BRACKET N CODE DESCRIPTION 021 0000 0001 TORCH CONNECTORS COMPLE TE KIT 1 016 5001 0822 SLEEVE HOSE ADAPTER FOR RUBBER HOSE 2 016 0007 0001 HOSE CLAMP 11 13 3 016 0007...

Страница 74: ...RLD Cod 006 0001 1820 25 05 2018 V 2 6 Cruiser 322 402 502AC DC Power Pulse 322 402 502AC DC 74 ENGLISH Antwerpsesteenweg 949 9041 Gent Oostakker info welda be www welda be T 32 0 9 355 74 26 F 32 0 9...

Страница 75: ...RLD Cod 006 0001 1820 25 05 2018 V 2 6 Cruiser 322 402 502AC DC Power Pulse 322 402 502AC DC 75 ENGLISH Antwerpsesteenweg 949 9041 Gent Oostakker info welda be www welda be T 32 0 9 355 74 26 F 32 0 9...

Страница 76: ...Cod 006 0001 1820 25 05 2018 V 2 6 Antwerpsesteenweg 949 9041 Gent Oostakker info welda be www welda be T 32 0 9 355 74 26 F 32 0 9 355 92 01...

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