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REHM FOCUS.ARC P Series Operating Instructions Manual

Mig/mag impulse welding systems
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OPERATING INSTRUCTIONS
MIG/MAG impulse welding systems
FOCUS.ARC P
MEGA.ARC P AND S
REHM SCHWEISSTECHNIK

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Summary of Contents for REHM FOCUS.ARC P Series

  • Page 1   OPERATING INSTRUCTIONS MIG/MAG impulse welding systems FOCUS.ARC P MEGA.ARC P AND S REHM SCHWEISSTECHNIK...
  • Page 2 05/05/2022  REHM GmbH u. Co. KG, Uhingen, Germany 2022 The content of this description is the property of REHM GmbH u. Co. KG The copying and distribution of this document, its use and communication of its contents are strictly prohibited unless expressly authorized.

  • Page 3: Table Of Contents

    List of contents List of contents INTRODUCTION ..........................6 Foreword ............................6 General description ........................7 1.2.1 The principle of the inert gas metal welding process ............... 8 1.2.2 Intended use ............................ 8 Symbols used ..........................9 SAFETY INSTRUCTIONS ......................10 Warning symbols in these operating instructions ..............
  • Page 4 List of contents Display panel Voltage (V) ......................40 Display panel Dynamic correction (SDI) ................... 40 Display panel LBL correction ....................40 Display panel Material thickness ....................40 5.10 Display panel Wire feed speed ....................40 5.11 Characteristic curve info bar ..................... 40 SUBMENUS ..........................
  • Page 5 List of contents 11.1 Safety instructions ........................66 11.2 Checks before switching on ....................... 66 11.3 Connecting the grounding cable ....................66 11.4 Practical instructions for use ..................... 66 FAULT ............................69 12.1 Safety instructions ........................69 12.2 Table of faults ..........................69 12.3 Error messages ..........................

  • Page 6: Introduction

    Only components of the highest quality are used in FOCUS.ARC P/S and MEGA.ARC P/S welding systems. To enable a long service life even under the toughest conditions all REHM equipment is manufactured using only parts that comply with our strict quality demands.

  • Page 7: General Description

    Introduction General description Figure 1: FOCUS.ARC P450 WS (Figure does not illustrate standard equipment)

  • Page 8: The Principle Of The Inert Gas Metal Welding Process

    REHM welding machines are, except when this is expressly stated in writing by REHM, only for sale to commercial / industrial users and are only intended to be used by commercial / industrial users. The machines may only be operated by persons who trained in the use and maintenance of welding equipment.

  • Page 9: Symbols Used

    Introduction Symbols used  Typographic Enumerations proceeded by a bullet point: General enumerations distinctions  Enumerations proceeded by a square: Work or maintenance steps that must be performed in the order listed.  Section 2.2, Warning symbols on the system Cross section: here to Section 2.2, Warning symbols on the system Bold text is used for emphasis Note!

  • Page 10: Safety Instructions

    Safety information Safety instructions Warning symbols in these operating instructions This or a symbol that more accurately specifies the risk can be found in all Warnings and of the safety instructions given in these operating instructions where there symbols is danger to life and limb. One of the signal words below (Danger!, Warning!, Caution!) is used to indicate the severity of the risk: Danger!

  • Page 11: Notes And Requirements

    REHM welding machines are, except when this is expressly stated in writing by Applications REHM, only for sale to commercial / industrial users and are only intended to be used by commercial / industrial users. The FOCUS.ARC P/S and MEGA.ARC P/S MIG/MAG gas welding equipment...
  • Page 12 See also the information on repair and maintenance, operating safety and functional reliability. These operating instructions are not a substitute for the practical teaching by the REHM service personnel. Documentation for any additional operation that may be present must also be observed.

  • Page 13: Unit Description

    Function description Unit description Figure 2: FOCUS.ARC P 450WS with case and water cooling unit Front view (Figure does not illustrate standard equipment)
  • Page 14 Function description Figure 3: FOCUS.ARC P 300W, compact and water cooled Front view (Figure does not illustrate standard equipment)
  • Page 15 Function description Figure 4: FOCUS.ARC P 450 Rear view of different design variants (Figure does not illustrate standard equipment...
  • Page 16 Function description Figure 5: FOCUS.ARC P 450 (wire feed case unit) Front view with separate feed case (Figures does not illustrate standard equipment)
  • Page 17 Function description Figure 6: FOCUS.ARC P 450 (compact unit) Front view of different design variants (Figures does not illustrate standard equipment)
  • Page 18 Function description Figure 7: FOCUS.ARC P wire feed case Figure 7: FOCUS.ARC P back of the Control panel...
  • Page 19 Function description Symbol Function / description Control panel - See "Description of controls" Control panel push and rotary encoder Welding torch connection (Euro connection) Remote control socket (7 pin) Connection coolant supply (Blue) Connection coolant return (red) Main switch for switching on/off the welding current source Current socket "negative"...

  • Page 20: Functional Description

    Function description Functional description Overview of the operating elements MEGA.ARC P/S Figure 9: Operating element and main screen FOCUS.ARC P...

  • Page 21: Control Panel Description

    Function description Control panel description 4.2.1 Operating elements Controls Function Main screen Operation via rotary encoder with push- knob and buttons for menu selection in the 4 corners of the screen Fig. 10 Main screen Function buttons (from left to right) Submenu List of all Button...

  • Page 22: Operating Elements

    Function description 4.2.2 Operating elements Figure 14: Screen functions Symbols Description / function Corner menu welding processes Corner menu operating modes 2 cycle 2 cycle with slope-down 4 cycle 4 cycle with slope-down Spot Spot with slope-down 2 cycle Interval 2 cycle Interval with slope-down 4 cycle Interval 4 cycle Interval with slope-down...
  • Page 23 Function description Symbols Description / function Corner menu characteristic curve Material group Material Diameter Process Number Corner menu welding process FOCUS.ARC FOCUS.PULS FOCUS.ROOT POWER.ARC (GMAW) POWER.PULS (Selection depending on the selected filler material and equipment of the system) Display panel Welding current (A) Display panel Voltage (V) Display panel Material thickness (mm)
  • Page 24 Function description Symbols Description / function BF12 Sub menu buttons BF13 GMAW-Parameters BF14 Job Memory BF15 Setup (Settings) BF16 Language BF17 Back button “Home” and “Back” BF18 Fault message Left in the characteristic curve info BF19 Display Operation and excess temperature...

  • Page 25: Switching On

    Switching on The FOCUS.ARC P/S and MEGA.ARC P/S welding systems are started with the mains switch. The screen shows the Rehm logo and the unit type for approximately 10 seconds. The display then switches to the main screen [Fig. 10 Main screen].

  • Page 26: Corner Menu Functions

    MIG/MAG (MSG inert gas metal welding) Turning and pressing the rotary encoder [Fig. ] selects and confirms the process. Pressing the button [BF17] "Back or "Rehm" returns to the main screen [Fig. ]. 5.1.1 GMAW With stepless GMAW, there are very different material transitions and also different arc types depending on the selected arc power and the shielding gas used, see also point 5.4 (welding process).

  • Page 27: Corner Menu Operating Mode (Top Right)

    Function description Corner menu operating mode (top right) The menu Operating modes [BF2] is activated by pressing the button at the top right of the keypad Fig. This allows the selection of the operating modes 1. 2 cycle 2. 2 cycle with slope-down 3.
  • Page 28 Function description Current Hotstart current Welding t (s) Hotstart Post flow Pre flow Hotstart time Time time Slope Figure 15: 2 cycle operating mode procedure with Hotstart...

  • Page 29: Cycle Operating Mode With Slope-Down (Slope)

    Function description 5.2.2 2 cycle operating mode with slope-down (Slope) 2 cycle operating mode procedure with slope-down (Slope):  1. cycle Operate the torch trigger The inert gas solenoid valve opens  After the set gas pre-flow time has expired the power unit is switched on ...

  • Page 30: Cycle Operating Mode

    Function description 5.2.3 4 cycle operating mode 4 cycle welding is recommended for longer welding seams. 4 cycle operating mode procedure:  1. cycle Operate the torch trigger The inert gas solenoid valve opens  After the set gas pre-flow time has expired the power unit is switched on ...

  • Page 31: Cycle Operating Mode With Slope-Down (Slope)

    Function description 5.2.4 4 cycle operating mode with slope-down (Slope) 4 cycle operating mode procedure with slope-down (Slope):  1. cycle Operate the torch trigger The inert gas solenoid valve opens  After the set gas pre-flow time has expired the power unit is switched on. ...

  • Page 32: Spot

    Function description 5.2.5 Spot The spot welding mode is recommended for welding with a fixed spot welding time from 0.1 seconds. The stationary welding process runs with a fixed spot welding time, unless the trigger is released prematurely during the welding. The program runs to the end after expiry of the set spot welding time or after releasing the torch trigger during the welding.

  • Page 33: Spot With Slope-Down (Slope)

    Function description 5.2.6 Spot with slope-down (Slope) Spot operating mode procedure with slope-down (Slope):  1. cycle Operate the torch trigger The inert gas solenoid valve opens  After the set gas pre-flow time has expired the power unit is switched on ...

  • Page 34: Cycle Interval

    Function description 5.2.7 2 cycle interval Interval welding is defined as spot welding with defined pause times. This makes possible apply thinnest filler materials. Interval welding is only possible in the 2 cycle operating mode. Welding in the interval welding mode is recommended for welding with a fixed break welding time from 0.01 seconds.

  • Page 35: Cycle Interval With Slope-Down (Slope)

    Function description 5.2.8 2 cycle interval with slope-down (Slope) 2 cycle interval operating mode procedure with slope-down (Slope):  1. cycle Operate the torch trigger The inert gas solenoid valve opens  After the set gas pre-flow time has expired the power unit is switched on ...

  • Page 36: Cycle Interval With Hot-Start

    Function description 5.2.9 4 cycle interval with Hot-start 4 cycle interval operating mode procedure with Hot-start  1. cycle Operate the torch trigger The inert gas solenoid valve opens  After the set gas pre-flow time has expired the power unit is switched on ...

  • Page 37: Cycle Interval With Slope-Down (Slope)

    Function description 5.2.10 4 cycle interval with slope-down (Slope) 4 cycle interval operating mode procedure with slope-down (Slope)  1. cycle Operate the torch trigger The inert gas solenoid valve opens  After the set gas pre-flow time has expired the power unit is switched on ...

  • Page 38: Corner Menu Characteristic Curve

    Function description Corner menu characteristic curve The material, the wire diameter of the inserted welding wire, the gas and the welding process can be selected and adjusted in the corner menu characteristic curve [BF3]. The selected characteristic curve is displayed on the main screen [BF11].

  • Page 39: Focus.root

    Function description 5.4.3 FOCUS.ROOT The FOCUS.ROOT welding process can be selected for root welding.  Controlled short electric arc  Energy-controlled bead detachment  Perfect root coverage  Easily modulated melt  Reduced spatter  Optimised arc energy for root welds ...

  • Page 40: Display Panel Welding Current (A)

    Function description Display panel Welding current (A) The required display panel "welding current" [BF5] can be selected by actuating the rotary encoder. The welding current can be set by turning the rotary encoder. The setpoint of the welding current is displayed in idle mode. The actual welding current is displayed during welding.

  • Page 41: Submenus

    1. One level back by acknowledging a setting 2. One level back by pressing the "Back" button 3. Completely back to the main screen with the button "Main menu" (Rehm). GMAW-Parameters With the welding parameters, the user can individually set the most important parameters for welding, such as: Gas pre-flow time, Sneak in, etc.
  • Page 42 Function description Figure 25: Submenu MSG parameters Figure 26: Details GMAW-Parameter...

  • Page 43: Explanation Of Welding Parameters

    Function description 6.1.3 Explanation of welding parameters 1 Gas pre-flow time Time between switching on the gas valve and the start of the creep in. This parameter depends on the selected characteristic curve, i.e. the gas pre-flow time can be set individually for each characteristic curve. 2 Sneak in wire speed Adjustment of the sneak in speed.
  • Page 44 Function description 13 I1 AL-correction The arc length for current 2 can be continuously adjusted by turning the rotary encoder. 14 Pulse time T2 Determines the length of time during which current 2 is used for welding. 15 Lowering jump Amount of a current value to which the welding current is suddenly reduced.

  • Page 45: Language Menu

    Function description Language menu The available languages are displayed as flags in a selection list. Use the cursor to select a language and confirm by pressing the rotary encoder. The language becomes active immediately. The selected language is illustrated by a box with cross. Figure 27: Sub menu Language selection [BF14]...

  • Page 46: Saving And Loading Jobs

    Function description Saving and loading jobs The Jobs submenu allows loading, saving and deleting of up to 500 jobs. The jobs can be saved and loaded under a freely selectable name in a freely selectable folder. Once the unit settings for recurring welding tasks have been determined, they can be quickly recalled and reset on the welding unit.
  • Page 47 Function description  The query may appear: Save as new job or overwrite?  Enter the desired name in the job memory by turning and pressing the rotary encoder (e.g. name of an employee, name of a customer and/or material). The job name can be up to 40 characters long. ...

  • Page 48: Load Job

    Function description 6.3.2 Load job  Pressing the "Submenus" button [BF12] accesses a selection list (drop down list) for the existing submenu.  Select the Job folder by turning and pressing the rotary encoder  Select the required field by turning and pressing the rotary encoder. The selected field has a blue frame.
  • Page 49 Function description Figure 31: View job memory / job preview Figure 32: Main view with active job...

  • Page 50: Edit Jobs And Folders

    Function description 6.3.3 Edit jobs and folders  Pressing the "Submenus" button [BF12] accesses a selection list (drop down list) for the existing submenu.  Select the desired function by turning and pressing the rotary encoder  Press the "Home" button to return to the main screen. Figure 33: Edit jobs and folders...
  • Page 51 Function description Job: Load By pressing this function you can load the selected job JOB: Copy By pressing this function, the selected job is copied to the clipboard. The job can then be pasted into another folder as a copy. JOB: Paste This function is only active if a job was previously copied to the clipboard.

  • Page 52: Setup Submenu

    Function description Setup submenu Functions and processes can be defined very conveniently and clearly in the Setup submenu. By turning the push and turn control [Fig. 13] the desired setting is selected.  The settings are logically structured in various subfolders. Some settings depend on the selected characteristic, the selected process, the equipment of the welding system, etc..
  • Page 53 Function description Designation Adjustment Description Factory settings Characteristic curves All settings (welding parameters) are reset to factory settings. Does not apply to: job Screen: Color scheme Bright / Dark Color change for optimal contrast Display Mirror: X No / Yes Display Mirror: Y No / Yes Menureset...
  • Page 54 Function description Welding AL control type Voltage / wire feed Double Pulse: Active / Inactive Allows for better heat control and seam flaking Double Pulse Slope: 0: fast to current 2 T1/T2 5: slowly to current 2 Double Pulse Slope: 0: fast to current 1 T2/T1 5: slowly to current 1...

  • Page 55: Welding Circuit: Detect

    Function description Welding Circuit: Detect The arcing behavior is e.g. highly dependent on the welding circuit. For  example, a long ground cable or intermediate hose package can lead to a significant shortening of the arc length. This in turn can cause heavy spattering.

  • Page 56: Control Lamps

    Function description Control lamps Symbol Description Operation/ The symbol OPERATION in black indicates that there is an excess temperature open circuit voltage at the torch or electrode holder. [BF20] The symbol is located on the left in the characteristic curve info bar The symbol illuminates red and flashes in the event of excess temperature.

  • Page 57: Threading

    Function description Other functions Threading The threading function is used to thread the welding wire into the torch hose set without current. The welding wire is threaded into the torch hose set by means of the push button above the feed unit (Fig. 4). By pressing the pushbutton "Threading", threading is carried out for 2 seconds at reduced speed.

  • Page 58: External Cooling Of The Power Units

    Function description External cooling of the power units The power units of the REHM FOCUS.ARC P/S or MEGA.ARC P/S systems are designed for high operational reliability. Optimum heat dissipation with minimum noise generation is achieved by the targeted placement of the cooling fan and the power components.

  • Page 59: Accessories And Options

    Accessories and options Accessories and options These operating instructions are based on the accessories approved by REHM. Unit versions, accessories and options MACHINES WITHOUT WIRE FEED CASE (choose undercarriage separate) FOCUS.ARC P 300 1,0/1,2mm 1307055 FOCUS.ARC P 300 W 1,0/1,2mm 1307056 FOCUS.ARC P 350 1,0/1,2mm...
  • Page 60 Accessories and options ACCESSORIES Intermediate hose pack gas cooled Intermediate hose pack MIG/MAG 50mm² 1,4m G 12p FA/MA/SP 7505000 Intermediate hose pack MIG/MAG 50mm² 5m G 12p FA/MA/SP 7505001 Intermediate hose pack MIG/MAG 50mm² 10m G 12p FA/MA/SP 7505002 Intermediate hose pack MIG/MAG 70mm² 1,4m G 12p FA/MA/SP 7505010 Intermediate hose pack MIG/MAG 70mm²...
  • Page 61 Accessories and options Torch MAG W 440D 5m 7601726 Torch MAG W 540D 3m 7601728 Torch MAG W 540D 4m 7601730 Torch MAG W 540D 5m 7601732 Torch MAG W 340D 7 3m UD 7601717 Torch MAG W 340D 7 4m UD 7601719 Torch MAG W 340D 7 5m UD 7601721...
  • Page 62 Accessories and options Trolley 7532026 Mounting kit FA/MA trolley 2103040 FEED ROLLER FOR WIRE FEED UNIT Single feed rollers for massive wire Feed roller 0,6/0,8mm massive 4/2 7503054 Feed roller 0,8/1,0mm massive 4/2 7503055 Feed roller 1,0/1,2mm massive 4/2 7503053 Feed roller 1,2/1,6mm massive 4/2 7503056 Feed roller 0,9/1,1mm massive 4/2...

  • Page 63: Commissioning

    (previously VGB 15) must be observed. 10.3 Positioning the welding unit Place the REHM welding system so that the welder has sufficient space in front of the unit to adjust and operate the controls. Transport the unit only under compliance with the applicable accident prevention regulations.

  • Page 64: Connecting The Welding Unit

    Always close the bottle valve after completing work. Observe the regulations of the respective professional associations. 10.5 Cooling the welding unit Place the REHM welding unit so that the air entry and exit ports are not obstructed. The machine can only achieve the specified duty cycle with sufficient ventilation.

  • Page 65: Connecting The Torch

    Commissioning 10.8 Connecting the torch For the connection of the GMAW welding torch there is a special connection on the housing (Euro central connection), through which the connections for the welding current, the probe lines and the gas are made. If water-cooled torches are used, the cooling water hoses are connected via quick couplings.

  • Page 66: Operation

    Warning! REHM welding equipment should be operated only by persons who are trained and instructed in the use, maintenance and the safety regulations concerning welding systems. 11.2 Checks before switching on It is a requirement that ...
  • Page 67 Wire liner Wire liners must be selected to match the various different types of material and wire gauges. The range for this can be found in the REHM welding accessories catalogue. In addition, please refer to the instructions of the torch manufacturer (see operating instructions).
  • Page 68 Operation still allow the wire to be transported safely. In the case of steel and stainless steel, the pressure should be so strong that the wire coil can still be stopped manually while the drive is running. ATTENTION: In the welding shop, the side wall that protects the wire feed area from access must be closed to avoid the risk of injury (e.g.

  • Page 69: Fault

    Fault Fault 12.1 Safety instructions Warning! If a fault occurs that represents a hazard to persons, systems and/or the environment, switch off the system immediately and secure against restarting. Only restart operations with the system after the fault has been eliminated and no hazard exists for persons, machines and/or the environment.
  • Page 70 Fault No inert gas Cause: Remedy: Bottle empty Check Pressure reducer defective Check Hose kinked Check Machine gas valve defective Service required ! Arc sputters and jumps Cause: Remedy: Contact tip worn Replace contact tip Feed rollers have incorrect diameter Use feed rollers with correct diameter Wire liner very dirty Replace wire liner...

  • Page 71: Error Messages

    Fault 12.3 Error messages Error Error Cause Elimination number Mains voltage is below the Switch the unit off and check the 1 000 Mains undervoltage tolerance range mains voltage Mains voltage is above the Switch the unit off and check the 2 000 Mains overvoltage tolerance range...

  • Page 72: Maintenance And Repair

    REHM original spare parts. If maintenance or repair work is performed on this unit by persons who have not been trained and authorised to carry out the work by REHM, then claims against REHM become void. Before beginning cleaning work the unit must be switched off and disconnected from the mains supply.

  • Page 73: Maintenance Table

    13.3 Cleaning the inside of the unit If the REHM welding unit is used in a dusty environment the inside of the unit must be cleaned at regular intervals by blowing out or vacuuming. The frequency of this cleaning depends on the respective conditions of use, however, it should be carried out at least twice a year.

  • Page 74: Cooling Water Check

    Dispose of these agents at appropriate collection points for hazardous substances. If maintenance or repair work is performed on this unit by persons who have not been trained and authorised to carry out the work by REHM, then and claims against REHM become void. 13.5 Proper disposal...

  • Page 75: Circuit Diagrams

    Circuit diagrams Circuit diagrams Figure 10: FOCUS.ARC P current source...
  • Page 76 Circuit diagrams Figure11: FOCUS.ARC P wire feed case...
  • Page 77 Circuit diagrams Figure12: FOCUS.ARC P water cooling...

  • Page 78: Characteristic Curve Current Source

    Components 14.1 Characteristic curve current source Name Part* Comments Item number + A0 ELKO EMV circuit board 250A-450A 690 0849 + A1 Power supply 690 0777 + A2 Main board 250A-300A 690 0747 350A-450A 690 0748 + A2.1/A2.2 Primary IMS 250A-300A 690 0852 350A-450A...
  • Page 79 Circuit diagrams Name Part* Comments Item number - M6 Water pump 230V/AC 410 0027 - M7/M8/M9 Fan Ø 120mm 230V/AC 410 0007 - S1 Main switch 420 0096 - S2/S3 Button “Gas” / “Wire feed” 420 0082 - T1/T2 Transformer 250A-300A 470 0411 350A-450A...

  • Page 80: Components And Spare Parts

    Components Components and spare parts 15.1 Characteristic curve wire feeding unit Wire feeding unit REHM Item no. 4000194: Pos. Name Part Comments Item number ø Wire infeed nipple - SET blue (Series) Plastic/ 0.6-1.6 2600400 ø 0.6/0.8 7503054 ø 0.8/1.0 7503055 ø...
  • Page 81 Components...
  • Page 82 Components...
  • Page 83 Components...
  • Page 84 Components...

  • Page 85: Technical Data

    Technical data Technical data Type overview Technical data FOCUS.ARC P Series | MEGA.ARC P and S Series Power class Setting range 20-300 20-350 20-400 20-450 Duty cycle (ED) at Imax. (40°C) Weld current at 100 % ED Idle voltage, approx.

  • Page 86: Index

    Index INDEX Intended Qualification A  and health Applications C  Changes to the system Checking cooling water and the cooler Checks before switching on Cleaning the inside of the unit Commissioning Connect grounding cable Connecting the grounding cable Connecting the welding unit Contact tips Cooling the welding unit E ...
  • Page 87 Index S  Safety Hazards of non-compliance Safety information 6, 10, 11 Operation Safety instructions Safety symbols Safety symbols Storing the operating instructions Symbols T  Table of faults Technical data Threading Torch accessories Type number Typographic distinctions U  Uncoiling mandrel setting W ...
  • Page 88 EC. Directive 2006/42/EC article 1, paragraph 2 the above mentioned products fall exclusively within the scope of the directive 2006/95/EC relating to electrical equipment designed for use within certain voltage limits. This declaration is given for the manufacturer: REHM GmbH u. Co. KG Schweißtechnik Ottostr. 2 73066 Uhingen Uhingen, 18/02/2019 submitted by R.
  • Page 92 Rehm GmbH u. Co. KG Schweißtechnik Tel.: +49 (0) 7161 3007-0 E-Mail: rehm@rehm-online.de Ottostraße 2 I 73066 Uhingen I Germany Fax: +49 (0) 7161 3007-20 Internet: www.rehm-online.de Date of issue 05/2022 | Item-no. 7302600...

This manual is also suitable for:

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