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AES Masterweld 204T Instruction Manual

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Cod.006.0001.1439
13/05/2013 v2.4
ENGLISH
MASTERWELD 204T
Instruction manual
GB

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  • Page 1 Cod.006.0001.1439 13/05/2013 v2.4 ENGLISH MASTERWELD 204T Instruction manual...
  • Page 2 Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH 2/31...
  • Page 3 Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH 3/31...

  • Page 4: Table Of Contents

    Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH INTRODUCTION ..............5 SPARE PARTS ..............25 FRONT PANEL ............... 5 ELECTRICAL DIAGRAM ............. 27 REAR PANEL ................. 6 17.1 204T ..................27 INSTALLATION ..............6 17.2 TORCH CONNECTOR ............29 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK . 6 17.3 REMOTE CONTROLLER CONNECTOR ......

  • Page 5: Introduction

     UP/DOWN torch or torch with potentiometer. the execution of the relevant operations.  liquid cooler for TIG torches. Masterweld 204T is an inverter DC TIG/MMA portable welding power FRONT PANEL source. The solidity of the components of this unit makes it a reliable working companion for workshop and outdoor applications.

  • Page 6: Rear Panel

    Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH REAR PANEL PREPARING FOR MMA WELDING 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. Choose the electrode based on the type of material and thickness of the workpiece to be welded.

  • Page 7: Preparing For Tig Welding

    Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH PREPARING FOR TIG WELDING 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.

  • Page 8: User Interface

    Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH MASTERWELD USER INTERFACE CODE SYMBOL DESCRIPTION This LED illuminates to show an anomaly in the operating conditions. See “ALARMS MANAGEMENT”(§ 9 page 12). When this LED illuminates the last voltage and current average values measured during welding are shown on following displays: D1 The “HOLD”...
  • Page 9 Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH When this LED illuminates the following parameter can be set: BASE TIME L21 + L22 When this LED illuminates the following parameter can be set: PULSED CURRENT FREQUENCY When this LED illuminates the following parameter can be set: DOWN SLOPE When this LED illuminates the following parameter can be set: FINAL CURRENT When this LED illuminates the following parameter can be set: POST-GAS Illumination shows that the following function has been activated: 2 times procedure...

  • Page 10: Unit Power-Up

    Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH 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 displays: D1 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 presets.

  • Page 11: Set-Up (Initial Set-Up Of The Welding Power Source)

    Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE) Set the welding power source ON/OFF switch to “O” to switch the unit off. Hold down the button. Set the welding power source ON/OFF switch to “I” to switch on the unit. SIMULTANEOUS ACTIONS The message appears for a few seconds on the following displays: D1 Press the button to confirm.

  • Page 12: Torch Loading

    Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH 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 must be filled 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.

  • Page 13: Derating

    Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH ADDITIONAL MESSAGE MEANING EVENT CHECKS MESSAGE All functions disabled. Exceptions: Check that the connection to the cooler is cooling fan. correct. The alarm message persists on the display until the first Check that the O/I switch is set to I and operation is performed on the user interface.

  • Page 14: Welding Parameters

    Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH WELDING PARAMETERS For a better understanding of the parameter functions described in the table, refer to the following diagram. (I1) MAX WELDING CURRENT (I2) BASE CURRENT (I3) FINAL CURRENT (I4) START CURRENT (t1) UP SLOPE TIME (t2) PEAK TIME (t3) BASE TIME (t4) DOWN SLOPE TIME...

  • Page 15: Base Time

    Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH Base time The arc strike procedure is as follows: Time during which current output is at the base value. Positioning of the torch with the electrode on the workpiece. Consequences of a higher value: Press the torch trigger and keep it pressed. ...

  • Page 16: Parameters Activation

    Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH 11.1 PARAMETERS ACTIVATION The welding parameters are available in accordance with the selected welding mode and procedure. Certain parameters are available only after other parameters or functions of the unit have been enabled or set. The table shows the settings required to enable each parameter.

  • Page 17: Welding Settings

    Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH WELDING SETTINGS 12.1 ELECTRODE WELDING (MMA) This button serves to select the following welding mode: 12.1.1 MMA PARAMETERS SETTING (1ST LEVEL) Press the button. Use the encoder to scroll the list of settings to edit. The acronym relative to the selected setting appears on the following displays: D1 Press the button to confirm.

  • Page 18: Mma Special Functions

    Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH 12.1.3 MMA SPECIAL FUNCTIONS Press this button to scroll the list of settings to edit. The value relative to the selected setting appears on the following displays: D1 Using the encoder, edit the value of the selected setting. Press any key (except S2) to save the setting and quit the menu.

  • Page 19: Dc Tig Parameters Setting (2Nd Level)

    Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH 12.2.2 DC TIG PARAMETERS SETTING (2ND LEVEL) Hold down the button for 3 seconds to gain access to the 2nd level menu. The LED illuminates. Use the encoder to scroll the list of settings to edit. The acronym relative to the selected setting appears on the following displays: D1 Press the button to confirm.

  • Page 20: Jobs Management

    Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH JOBS MANAGEMENT Personalised welding settings, or JOBs, can be saved in memory locations and subsequently uploaded. Up to 50 jobs can be saved (j01-j50). The settings of the SETUP menu are not saved. 13.1 SAVING A JOB This function is available when welding mode is not active.

  • Page 21: Torch Trigger Modes

    Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH number of the latest job used. Use the encoder to select the number of the job to be deleted. Exit without confirmation Press any button (except S4). This action will automatically close the menu. Exit with confirmation Press the button.

  • Page 22: Hf Welding

    Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH 14.4 4T HF WELDING 1. Bring the torch up to the work until the electrode tip is approximately 2 or 3 mm away. 2. Press (1T) and release (2T) the torch trigger. The arc strikes without contact with the workpiece and the voltage discharges (HF) cease automatically. The welding current reaches the preset value, by way of a up slope time, if programmed.

  • Page 23: Spot Hf Welding

    Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH 14.8 2T SPOT HF WELDING Press and release torch trigger procedure 1. Bring the torch up to the work until the electrode tip is approximately 2 or 3 mm away. 2. Press (1T) the torch trigger. The arc strikes without contact with the workpiece and the voltage discharges (HF) cease automatically.

  • Page 24: Technical Data

    Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH MASTERWELD TECHNICAL DATA Model 204T EN 60974-1 Construction standards EN 60974-3 EN 60974-10 Class A 1 x 230V~ ± 15 % / 50-60 Hz Supply voltage 1 x 115V~ ± 15 % / 50-60 Hz Dimensions ( L x D x H ) 400 x 160 x 260 mm Weight...

  • Page 25: Spare Parts

    Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH MASTERWELD SPARE PARTS 25/31...
  • Page 26 Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH N° CODE DESCRIPTION 011.0006.0031 HANDLE 011.0000.0115 COVER PLATE 050.0001.0092 MAINS FILTER BOARD 050.0002.0097 POWER BOARD 050.0002.0098 SNUBBER BOARD 032.0002.2003 ISOTOP DIODE 040.0003.1008 THERMAL CUT-OUT 032.0001.5012 PRIMARY RECTIFIER 011.0003.0055 SOCKET PROTECTION PLATE 010.0006.0044 COMPLETE FRONT PLASTIC PANEL 021.0001.0260 FIXED SOCKET 400 A 050.5031.9900...

  • Page 27: Electrical Diagram

    Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH ELECTRICAL DIAGRAM 17.1 204T 27/31...
  • Page 28 Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH 28/31...

  • Page 29: Torch Connector

    Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH 17.2 TORCH CONNECTOR 17.3 REMOTE CONTROLLER CONNECTOR cod. 021.0004.3360 cod. 021.0004.0602 Torch Torch with potentiometer Up & Down Torch 2 kOhm - 10 kOhm potentiometer Remote Controller 2 kOhm - 10 kOhm potentiometer Foot pedal controller 2 kOhm - 10 kOhm potentiometer 29/31...
  • Page 30 Cod.006.0001.1439 13/05/2013 v2.4 204T ENGLISH 30/31...
  • Page 31 Cod.006.0001.1439 204T 13/05/2013 v2.4 ENGLISH 31/31...

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