Weco Discovery 200AC/DC Instruction Manual
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Weco Discovery 200AC/DC Instruction Manual

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Cod. 006.0001.0340
15/04/2021 V.2.13
Discovery
200AC/DC
Instruction manual
Translation of original instructions
ENG

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Summary of Contents for Weco Discovery 200AC/DC

  • Page 1 Cod. 006.0001.0340 15/04/2021 V.2.13 Discovery 200AC/DC Instruction manual Translation of original instructions...
  • Page 2 Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD...

  • Page 3: Table Of Contents

    Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD INDEX INTRODUCTION ............................4 INTRODUCTION ............................5 INSTALLATION ............................6 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK ..............6 FRONT PANEL ............................. 6 REAR PANEL ............................... 7 PREPARING FOR MMA WELDING ......................8 PREPARING FOR TIG WELDING .......................

  • Page 4: Introduction

    Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD 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.

  • Page 5: Introduction

    Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD 1.1 INTRODUCTION Discovery 200 AC/DC is an advanced technology single-phase welding power source for AC and DC TIG welding operations. AC TIG functions are ideal for aluminium, magnesium and related alloys welding. AC TIG welding is optimized thanks to: Synergic arc ignition selection located on the front panel, it modifies the ignition according to electrode diameter. Advanced Soft AC-Square Waveform for outstanding welding quality through faster welding speed, bet- ter pool control and noise reduction. Mild steel, stainless steel and copper can be easily welded in DC TIG. Slow Pulse (0.1Hz-5.0 Hz) and Fast Pulse (5.0 Hz-250 Hz) are available in TIG DC. Special HF control provides 100 % rapid and precise arc ignition. Up to 3,25 mm diameter electrode welding is possible in MMA. Accessories/ancillary devices that can be connected to the unit: - Overcut device to protect the power source from power supply voltage spikes that could damage the electrical components.

  • Page 6: Installation

    Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD 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 characteristics of the mains power supply to which the equipment shall be connected are given in chapter entitled “12 TECHNICAL DATA” on page 54.

  • Page 7: Rear Panel

    Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD 2.3 REAR PANEL ○ Power cable. [Item 1]. • Total length (including internal part): 2,5 m • Number and cross section of wires: 3 x 2,5 mm • Power plug type: Schuko ○ Cooler group power feeding connector.[Item 2]. • Voltage: 230 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 ○...

  • Page 8: Preparing For Mma Welding

    Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD 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”.

  • Page 9: Preparing For Tig Welding

    Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD 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 switched off). 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.

  • Page 10: User Interface

    Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD COMMISSIONING 3.1 USER INTERFACE L12 L13 L14 L10 L11 STOP CODE SYMBOL DESCRIPTION This LED illuminates to confirm the presence of power on the output sockets. STOP This LED illuminates to show an anomaly in the operating conditions. STOP When this LED illuminates the following parameter can be set: SLOPE UP (s) When this LED illuminates the following parameter can be set: WELDING CURRENT (A) When this LED illuminates the following parameter can be set: SECOND CURRENT B-LEVEL When this LED illuminates the following parameter can be set: BASE CURRENT (A) Slow pulsed DC TIG: When this LED illuminates the following parameter can be set: PEAK...
  • Page 11 Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD CODE SYMBOL DESCRIPTION When this LED illuminates the following parameter can be set: SLOPE DOWN (s) When this LED illuminates the following parameter can be set: STARTING CURRENT (%/A) When this LED illuminates the following parameter can be set: POST-GAS (s) AC TIG mode: When this LED illuminates the following parameter can be set: AC FREQUEN- CY (Hz) - AC TIG mode: When this LED illuminates the following parameter can be set: AC TIG BAL- ANCE STOP STOP AC TIG mode: When this LED illuminates the following parameter can be set: ELECTRODE STOP DIAMETER(mm) This LED indicates that the current reference setting is imposed by the remote controller. Illumination shows that the following function has been activated: 2 stroke procedure.

  • Page 12: Unit Power-Up

    Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD CODE SYMBOL DESCRIPTION Press and release: the button enables the device to receive the welding current control signal from a remote controller. Press and release: press the button to select the parameter to be set. This button selects the torch trigger procedure. This button selects the welding mode. Data setting: The encoder sets the value of the selected parameter. Welding: The encoder sets the value of the following parameter: WELDING CURRENT STOP STOP Remote controller connector. 3.2 UNIT POWER-UP Set the welding power source ON/OFF switch to “I” to switch on the unit. First power-up or power-ups following a RESET procedure The welding power source sets up for welding with the factory pre-sets.

  • Page 13: Alarm Management

    Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD 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 finds it difficult to restore defaults. - Unidentified software problems that prevent the welding power source from functioning correctly. ○ Set the welding power source ON/OFF switch to “O” to switch the unit off. ○ Keeping both the S2 and S4 buttons pressed, set the generator power source SIMULTANEOUS ACTIONS] switch to “I” to turn on the equipment [ 3.4 TORCH LOADING...

  • Page 14: Mma Welding

    Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD MMA WELDING L12 L13 L14 SETTING L10 L11 STOP ACTIVATION ○ Press the S4 button to activate the MMA mode. L10 L11 L 20 ○ Using theencoder E1 , edit the value of the selected setting. The value is saved automati- cally. Tab. 2 - Parameters of the 1st level menu: MMA mode...

  • Page 15: Tig Welding

    Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD TIG WELDING 5.1 TIG WELDING - FIRST LEVEL MENU L12 L13 L14 SETTING L10 L11 STOP ACTIVATION SELECTION ○ Press the S4 button to activate the TIG mode. L10 L11 L 21 TIG DC CONTINUOUS...
  • Page 16 Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD Tab. 3 - Parameters of the 1st level menu: CONTINUOUS DC TIG mode SETTING DEFAULT WELDING CURRENT 80 A 200 A SECOND CURRENT B-LEVEL (This parameter is set as a percentage referred to the value of the 10 % 50 % 200 % following parameter: WELDING CURRENT) DOWN SLOPE 0.0 s...
  • Page 17 Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD Tab. 6 - Parameters of the 1st level menu: AC TIG mode SETTING DEFAULT WELDING CURRENT 80 A 200 A SECOND CURRENT B-LEVEL (This parameter is set as a percentage referred to the value of the 10 % 50 % 200 % following parameter: WELDING CURRENT) DOWN SLOPE 0.0 s...
  • Page 18 Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD - BASE CURRENT ○ Pulsed wave minimum current. - Consequences of a higher value: • - Faster creation of weld pool. • - Increase of heat-affected zone. - PEAK TIME ○ Time for which the current pulse is at the maximum value. - Consequences of a higher value: • - Greater width of the beading and greater welding penetration. • - Facility to make deeper cuts.
  • Page 19 Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD set as a percentage of the welding current or as an absolute value expressed in Amperes. The parameter is displayed but it is not used during the welding process when the following setting is present: MULTI TACK = ON The usefulness of having an adjustable initial welding current is that of avoiding welding the part with excessively high current values and thus potentially damaging it. Particularly useful when welding thin sheets. - AC INVERSION FREQUENCY ○ The frequency in TIG AC is the number of inversions by DC + to DC- as a unit of time (T1) and adjusted in Hertz (Hz). The reduction in the frequency value of the electric arc inversion tends to widen its size, therefore it is advisable 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 and therefore increases the concentration of the pool and the precision of the welding. It is therefore advisable to use high values of frequency for the welding of very thin thickness or for facings on edges of moulds - Consequences of a higher value: • Arc concentration. • Reduction of heat-affected zone. • Slower melt speed.
  • Page 20 Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD AC BALANCE BALANCE 0 DC+ (35%) DC- (65%) BALANCE + DC+ (50%) DC- (50%) BALANCE - DC+ (20%) DC- (80%) - ELECTRODE DIAMETER ○ The parameter optimizes the AC TIG welding arc strike on the basis of the diameter of the chosen electrode.
  • Page 21 Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD 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. STOP STOP STOP Tab. 7 - Table showing enabled Welding Parameters STOP STOP STOP STOP STOP MODE STOP → STOP STOP MENU PROCEDURE STOP STOP ↓...
  • Page 22 Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD STOP STOP STOP STOP STOP STOP STOP STOP MODE → STOP STOP MENU PROCEDURE STOP ↓ → PARAMETER ↓ 1° SLOPE UP 1° AC FREQUENCY 1° AC BALANCE 1° ELECTRODE DIAMETER 2°...

  • Page 23: Tig Welding - Second Level Menu

    Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD 5.2 TIG WELDING - SECOND LEVEL MENU L12 L13 L14 SETTING L10 L11 STOP ACTIVATION ○ Hold down the S2 button for 3 seconds to access the 2nd level menu. - The acronym relative to the setting to be edited appears on the following displays: D1. ○ Using theencoder E1 , edit the value of the selected setting. The value is saved automati- cally. Tab. 6 - Parameters of the 2nd level menu: - CONTINUOUS DC TIG, SLOW PULSED DC TIG, FAST PULSED DC TIG, AC...

  • Page 24: Torch Trigger Procedure

    Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD TORCH TRIGGER PROCEDURE L12 L13 L14 L10 L11 STOP SELECTION ○ Press the S3 button to select the desired PULSED TORCH mode. L10 L11 L 15 2 STROKE L 16...
  • Page 25 Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD FAST PULSED DC TIG AC TIG - 2 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 welding current reaches the pre-set value, by way of an up slope time, if programmed. ○ Release (2T) the trigger to start the weld completion procedure. ○ The current reaches the end current value in the time set in the down slope time parameter. ○ The arc is extinguished.
  • Page 26 Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD 1st TIME 2nd TIME WELDING CURRENT START CURRENT FINAL CURRENT SLOPE UP DOWN SLOPE POST GAS PRE GAS IGNITION - 4 STROKE LIFT: ○ Touch the workpiece with the torch electrode. ○ Press (1T) and keep the torch trigger pressed.
  • Page 27 Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD ○ The current reaches the end current value in the time set in the down slope time parameter. ○ The arc continues and the current output will be the value set in the end current parameter. ○ In these conditions the weld pool can be closed (crater filler current). ○ Release (4T) the trigger to extinguish the arc. ○ Gas delivery continues for the time set in the post gas parameter. 4th TIME 1st TIME 2nd TIME 3rd TIME WELDING CURRENT FINAL CURRENT STARTING CURRENT RAMP RAMP POST GAS PRE-GAS DESCENT...
  • Page 28 Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD PRESSURE AND RELEASE 1st TIME 2nd TIME 3rd TIME 4th TIME PRIMARY CURRENT SECOND CURRENT FINAL CURRENT STARTING CURRENT RAMP POST GAS PRE-GAS RAMP DESCENT IGNITION - 2 STROKE TACKING WELDING WITH HIGH FREQUENCY ARC STRIKE (2T SPOT HF) All our generators TIG HF have been provided with the spot-welding function. After having switched the...

  • Page 29: Technical Data

    Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD TECHNICAL DATA Waste electrical and electronic equipment (WEEE) Electromagnetic compatibility (EMC) Directives applied Low voltage (LVD) Restriction of the use of certain hazardous substances (RoHS) Construction standards EN 60974-1; EN 60974-3; EN 60974-10 Class A Equipment compliant with European directives in force Equipment suitable in an environment with increased hazard of electric shock Conformity markings Equipment compliant with WEEE directive ü Equipment compliant with RoHS directive RoHS Supply voltage 1 x 230 Va.c. ± 15 % / 50-60 Hz Mains protection...
  • Page 30 Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD 30% (40° C) 15.0 A 40% (40° C) 16.7 A Maximum Effective Supply Cur- rent 60% (40° C) 17.2 A 15.5 A 100 % (40° C) 20.0 A 15.6 A No-load voltage (U0) 88 V Reduced no-load voltage (Ur) 10 V 13.5 kV...

  • Page 31: Electrical Diagram

    Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD ELECTRICAL DIAGRAM...

  • Page 32: Remote 1" Connector

    Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD 8.1 TORCH CONNECTOR INTERNAL VIEW Code 021.0004.3360 Torch TORCH P.T. P.T. N.C. N.C. N.C. 8.2 REMOTE CONTROLLER CONNECTOR INTERNAL VIEW Code 021.0004.0602 FOOT PEDAL REMOTE CONTROL- Torch with Potentiometer REMOTE CONTROLLER...

  • Page 33: Spare Parts

    Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD SPARE PARTS...
  • Page 34 Cod. 006.0001.0340 Discovery 200AC/DC 15/04/2021 V.2.13 ENGLISH WELD THE WORLD N° CODE DESCRIPTION 005.0001.0008 BELT 011.0000.0161 COVER PLATE 050.0003.0027 HF BOARD 050.0001.0025 POWER BOARD 040.0003.1270 TERMAL SWITCH L= 200 mm 010.0002.0004 HF TRANSFORMER 044.0004.0004 INDUCTANCE 011.0008.0029 LATERAL PLATE 050.5154.0000 FRONT PANEL 10 014.0002.0002 KNOB 11 021.0001.0259...
  • Page 35 Discovery 200AC/DC Cod. 006.0001.0340 15/04/2021 V.2.13 ENGLISH WELD THE WORLD CODE DESCRIPTION 021.0000.0001 TORCH CONNECTORS COMPLETE KIT 016.5001.0822 HOSE ADAPTER 1/4 016.0007.0001 HOSE CLAMP Ø=11-13 016.0007.0709 HOSE CLAMP Ø=07-09 016.5001.0821 SLEEVE HOSE ADAPTER FOR RUBBER HOSE M10 021.0004.3360 AMPHT3360-001 M/5V. VOL. CONNECTOR 016.5001.1311 NUT M10 016.5001.0823...
  • Page 36 Cod. 006.0001.0340 15/04/2021 V.2.13 www.weco.it...

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