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CEA CONVEX 321 Operator's Manual

Multi-function inverter generator
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Operator's manual
READ CAREFULLY
CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A.
C.so E. Filiberto, 27 - 23900 Lecco - Italy
Tel. ++39.0341.22322 - Fax ++39.0341.422646
Cas. Post. (P.O.BOX) 205
E-mail: cea@ceaweld.com - web: www.ceaweld.com

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Summary of Contents for CEA CONVEX 321

  • Page 1 Operator’s manual READ CAREFULLY CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A. C.so E. Filiberto, 27 - 23900 Lecco - Italy Tel. ++39.0341.22322 - Fax ++39.0341.422646 Cas. Post. (P.O.BOX) 205 E-mail: cea@ceaweld.com - web: www.ceaweld.com...

  • Page 2: Table Of Contents

    ENGLISH Introduction Introduction Description Thank you for buying our product. In order to get the best performance out of the plant and ensure Operating features the maximum lifespan of its parts, the use and maintenance instructions contained in this manual must be read and strictly Technical data complied with, as well as the safety instructions contained Usage limits (IEC 60974-1)

  • Page 3: Technical Data

    CM / CP control panel manual), which protects the components inside the welding machine against dangerous overheating. After several minutes the overheat cut-off rearms automatically and the welder is ready for use again. Table 1 CONVEX 321 CONVEX 401 CONVEX 325 PULSE CONVEX 405 PULSE Model...

  • Page 4: How To Lift Up The System

    • The “S” usage class indicates that the generator can be em- ployed in environments with a high risk of electrical shocks. Table 1 CONVEX 321 CONVEX 401 CONVEX 325 PULSE CONVEX 405 PULSE...

  • Page 5: Loading Wire

    Loading wire • Fit the reel (diam. 300 mm) on the support so that the wire unrolls clockwise, and center the projecting reference on the 3 4 4 3 support with the relative hold on the reel. • Thread the end of the wire into the back guide (Pos. 1, Fig. A) on the drawing mechanism.

  • Page 6: Mig-Mag / Pulse Mig / Double Pulse Mig Welding

    2 - Welding 1) Switch the welding machine on by moving the power sup- ply switch to I (Pos. 6, Fig. B). 2) Make the adjustments and do the parameter settings on the CM / CP control panel (for further information see the CM / CP control panel manual).

  • Page 7: Aluminium Welding

    A fairly approximate indication of the average current to use in Aluminium welding the welding of electrodes for ordinary steel is given by the fol- lowing formula: To weld with aluminum wire proceed as follows: • Replace the drive rolls with special ones for aluminium wire. I = 50 ×...

  • Page 8: Tig Welding With "Lift

    Table 5 TIG welding with “Lift” ELECTRODE TYPE In the TIG process welding is achieved by melting the two met- Current adjustment field (A) al pieces to be joined, with the possible addition of material Ø ELECTRODE TIG DC from the outside, using an arc ignited by a tungsten electrode. (mm) Tungsten Tungsten...

  • Page 9: The Pointing Out Of Any Difficulties And Their Elimination

    The pointing out of any difficulties Replacing the digital interface PCB and their elimination Proceed as follows: • Unscrew the 4 screws fastening the front rack panel. The supply line is attributed with the cause of the most com- • Remove both the adjustment knobs. mon difficulties.

  • Page 10: Meaning Of Graphic Symbols On Machine

    Meaning of graphic symbols on machine Power supply switch Negative pole snap-in connector System for use in environments with in- Warning! creased risk of electroshock Before using the equipment you should Product suitable for free circulation in the carefully read the instructions included in European Community this manual Danger! Parts moving...
  • Page 11 2101AC34 CONVEX 321 - 401...
  • Page 12 2101AC33 CONVEX 325 PULSE...
  • Page 13 2101AD30 CONVEX 405 PULSE...
  • Page 14 Lista ricambi LEGGERE ATTENTAMENTE Spare parts list READ CAREFULLY CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A. C.so E. Filiberto, 27 - 23900 Lecco - Italy Tel. ++39.0341.22322 - Fax ++39.0341.422646 Cas. Post. (P.O.BOX) 205 E-mail: cea@ceaweld.com - web: www.ceaweld.com...
  • Page 15 236655 236655 Attacco Euro Euro connection 434243 434243 434243 434243 Tubetto guidafilo 120mm 120mm Wire guide tube 403611 403611 403611 403611 Attacco rapido Quick connection 420592 420592 420592 420592 Coperchio fisso con adesivo logo CEA Cover with CEA logo sticker...
  • Page 16 Tubo gas Gas tube Connettore alimentazione 419049 419049 419049 419049 Cooling system power connector impianto di raffreddamento Coperchio lato destro con 420594 420594 420594 420594 Right cover with CEA logo sticker adesivo logo CEA 414326 414326 414326 414326 Chiavistello Lock...
  • Page 17 CONVEX CONVEX CONVEX CONVEX Pos. Descrizione Description PULSE PULSE 404895 404895 404895 404895 Basamento Base 241852 241852 241852 241852 Mozzo bobina Spool holder 466159 466159 466159 466159 Supporto meccanismo di trascinamento Wire feed mechanism support Condensatore di protezione 488315 488315 488315 488315 Quick connection protection capacitor...
  • Page 18 (assembly) CONVEX CONVEX CONVEX CONVEX Pos. Descrizione Description PULSE PULSE 435760 435760 435760 435760 Interruttore alimentazione Mains switch 427679 427679 427679 427679 Filtro EMC EMC Filter 425938 425938 425938 425938 Elettrovalvola Solenoide valve 418746 418745 Condensatore DC-LINK DC-LINK capacitor Scheda power source e 377193 377193 377193...
  • Page 19 CONVEX CONVEX CONVEX CONVEX Pos. Descrizione Description PULSE PULSE 247497 247497 247497 247497 Induttore secondario Secondary inductor 478867 478867 478867 478867 Termostato primario Primary thermostat 286046 286046 286046 286046 IGBT primario Primary IGBT 377194 377194 377194A 377194A Scheda inverter primario Primary inverter PCB 455513 455513...
  • Page 20 IT Complessivo meccanismo di EN Wire feeder unit assembly with 4 rolls trascinamento a 4 rulli 16 1 Pos. Cod. Descrizione Description 449041 Chiavetta Woodruff Key 441210 Molla di pressione Ø 2 mm Pressure spring Ø 2 mm 437075 Dispositivo di pressione rulli (con molla 2 mm) Pressure Adjustment Unit (2 mm spring) 676510 Spina elastica...
  • Page 21 Tabella A - RULLI UTILIZZABILI Table A - SUITABLE ROLLS RULLI STANDARD STANDARD ROLLS SOLO PER ACCIAIO FOR HARD WIRE ONLY Rullo superiore piatto Pressure flat roll per tutti i diametri con boccola for all diameters with bushing Rullo inferiore a doppia cava Ø 37 mm Feed roll double groove Ø...
  • Page 22 4) Il numero di matricola EXAMPLE ESEMPIO N. 2 pieces code n. 488315 - for CONVEX 321 - 400 V - 50/60 N° 2 pezzi, codice n. 488315 - per l’impianto CONVEX 321 - Hz - Serial number ............. 400 V - 50/60 Hz - Matricola n° ........
  • Page 23 Operator’s manual READ CAREFULLY CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A. C.so E. Filiberto, 27 - 23900 Lecco - Italy Tel. ++39.0341.22322 - Fax ++39.0341.422646 Cas. Post. (P.O.BOX) 205 E-mail: cea@ceaweld.com - web: www.ceaweld.com...
  • Page 24 ENGLISH Introduction Special processes Control panel Electrode (MMA) KEY AND KNOB COMMANDS 1 - WELDING PROCESS SELECTION DISPLAY AND LED INDICATIONS 2 - SELECTION OF WELDING PROGRAM 3 - SPECIAL FUNCTIONS “Fx” SELECTION Switching on the welding machine and initial screen 4 - PRE-SETTING 5 - WELDING 6 - HOLD...

  • Page 25: Control Panel

    TWO STROKE (2T) Control panel 2T LED ( ) switched on Pressing the TORCH TRIGGER starts the welding cycle, which KEY AND KNOB COMMANDS will stop when it is released. FOUR STROKE (4T) 4T LED ( ) switched on ▪ ENCODER knob - A ▪ ENCODER knob - V 1) Pressing and releasing the TORCH TRIGGER will start the welding cycle.

  • Page 26: Display And Led Indications

    ■ SPECIAL FUNCTIONS key “Fx” (T ≥ 2 s) ■ PARAMETER DISPLAY screen - V This key is used to display and edit some parameters (ADJUST- This Display shows the values / numbers (set or measured) of the ABLE FUNCTIONS “Fx”) that are necessary and fundamental for following parameters (if active): welding and that have already been set by the manufacturer in • ARC LENGTH ADJUSTMENT (...

  • Page 27: Loading Of The Wire

    2) On both displays appears a running string that indicates the WARNING: Changes to values are immediately activated (no fur- VERSION OF THE SOFTWARE installed on the welder. ther confirmation is required and they will be displayed immedi- The rotation of one of the two ENCODER Knobs - A (E1) or ately) or, at least they will become active the next time welding is V (E2) by the operator during the display of the string version done.
  • Page 28 Table 1 SETTINGS RANGE WELDING PROCESS MIG-MAG WELDING MODE MIG MAG / PULSE FUNCTION DISPLAY Spot Stitch FACTORY RANGE Cycle ADJUSTABLE FUNCTIONS “Fx” Fx > 3s MIG-MAG process PRE GAS 0.1s (0.0 ÷ 2.0)s ● ● ● ● ● ● ●...

  • Page 29: Setup Menu

    3) To exit the SPECIAL FUNCTIONS “Fx” menu, push and re- TIMER ARC ON lease the SPECIAL FUNCTIONS “Fx” (T3) key once. This indicates the actual time the machine was used for welding. WARNING: This time can only be zeroed using the FACTORY DE- FAULT (FAC in the SEtUP menu) for the welding plant.

  • Page 30: Error Log

    ERROR LOG TEST This allows the operator to know about the error states that have This configuration allows the operator to check that some func- arisen on the welding plant. tions of some devices. 1) Rotate the ENCODER - A (E1) knob, until both the displays 1) Rotate the ENCODER - A (E1) knob, until both the displays (D1-D2) read Err Log.

  • Page 31: Menu Special Functions

    MOTOR CALIBRATION (Mot CAL) Menu SPECIAL FUNCTIONS From the SEtUP menu, push the PRG key (T5) for more than 3 ATTENTION: This procedure allows you to calibrate the wire seconds to access the SPECIAL FUNCTIONS menu, which pro- speed (only in MIG welding processes). vides access to additional functions that can only be managed by an expert, responsible operator.

  • Page 32: Arc Length Adjust

    Calibration parameter SM3 (MAXIMUM SPEED) CYCLE Then turn the ENCODER - A knob (E1) until the PARAM- If enabled, this function allows the operator to have a further ETER DISPLAY - A screen (D1) shows the SM3 parame- welding mode (CYCLE) available, in MIG (pulsed, double pulsed, ter.

  • Page 33: Password

    RAMETERS - A (D1) display shows the SEr function, and the DISPLAY PARAMETERS - V (D2) display reads nUM. IMPORTANT: If the password is lost, contact CEA’s technical service department. 2) When the PRG key is pushed, a 16-character text will pass...

  • Page 34: Mig-Mag Synergic / Mig Pulse / Double Pulsed Mig

    3D) To access the vision.COLD welding process: rotate the EN- MIG-MAG synergic / MIG pulse CODER knob - A (E1) until obtaining on the PARAMETER / double pulsed MIG DISPLAY screen - A (D1) and the writing CLd. Start the welder by pressing the switch, located on the back pan- el, at the position I.

  • Page 35: Welding Mode Selection

    WARNING: This table is merely an example, the welding programs the factory setting value. Higher numbers correspond to more can be updated and extended. See the table on the welding ma- burning of the wire. chine for the correct list of the programs available. • POST GAS (PoG) - Provides an additional quantity of gas for a defined time, after welding ends.

  • Page 36: Pre-Setting

    5 - PRE-SETTING During the welding the operator can change the following param- Before welding it is possible to set the following parameters: eters: • THICKNESS OF WELDED ITEM ( • WELDING CURRENT ( ). THICKNESS OF WELDED ITEM • WIRE SPEED ( • ARC LENGTH ADJUSTMENT ( WELDING CURRENT • ELECTRONIC INDUCTANCE (...

  • Page 37: Mig-Mag Manual

    • CRATER START TIME (F10) - This function defines the time MIG-MAG manual in which the current remains at the value of CRATER START SPEED or CRATER START VOLTAGE. Start the welder by pressing the switch, located on the back pan- • CRATER START SLOPE (F11) - Time taken to go from the CRA- el, at the position I.

  • Page 38: Pre-Setting

    • Hold the SAVE “MEM” key (T2) down for at least 2 consecu- • PARAMETER DISPLAY screen - V (D2) tive seconds. T ≥ 2 s WELDING VOLTAGE ELECTRONIC INDUCTANCE • The program in use has now been completed successfully. To confirmation the above, the control panel of the welder performs a short operation of MACHINE CHECK (all of the LED stay lit simultaneously so as to verify their actual operation), the gen-...

  • Page 39: Special Processes

    Special processes The welding machine can be equipped with additional welding programs, by having some software packages activated, against payment and by request. CEA has designed and developed the following SPECIAL PROCESSES. vision.COLD (CLd) 2 - SELECTION OF WELDING PROGRAM (excluding CONVEX MOBILE 201 model)

  • Page 40: Special Functions "Fx" Selection

    3 - SPECIAL FUNCTIONS “Fx” SELECTION 4 - PRE-SETTING Before welding it is possible to set the following parameters: ADJUSTABLE FUNCTIONS “Fx” Fx > 3s SETTINGS RANGE FUNCTION DISPLAY WELDING CURRENT FACTORY RANGE HOT START 0 ÷ 100 ARC FORCE 0 ÷...

  • Page 41: Hold

    6 - HOLD This function automatically starts itself at the conclusion of eve- ry welding operation welding and it is indicated to the operator by means of a flashing light of the HOLD FUNCTION LED for a spe- cific amount of time. Once the welding has been terminated, for about 15 seconds, both the DISPLAYS should show the same val- ues of the parameters during the welding.

  • Page 42: Pre-Setting

    ■ PROGRAM DEFAULT (dEF) 4 - WELDING During the welding the display shows: • PARAMETER DISPLAY screen - A (D1) WARNING: If carried out, this operation resets the program in use to the factory default settings. To carry out the reset of the settings / parameters, proceed in the WELDING CURRENT following manner: • Rotate the ENCODER - A (E1) knob until both the displays read...

  • Page 43: Job

    To interrupt the HOLD function and go back to the PRESETTING WARNING: If all the automatic welding points (JOBS) are occu- phase before 15 seconds have passed, simply turn one of the two pied, the check automatically goes to the first automatic welding ENCODER (E1-E2) knobs.

  • Page 44: Welding

    4 - WELDING 7 - DELETING A JOB SAVED During the welding the display shows the values, if possible meas- In JOB mode, holding down the PARAMETER SELECTION - A ured, of the active parameters, based on the type of welding pro- (T1) and PARAMETER SELECTION - V (T4) keys down simulta- cess, memorised within the selected JOB.
  • Page 45 Error condition This paragraph describes the error conditions that may arise on the welding machine, the codes and messages shown on both op- erator interface displays, and the diagnoses for attempting to cor- rect and resolve them. In an “error condition” the operator’s interface uses both displays to display: ▪ ERROR CONDITION display ▪ ERROR DESCRIPTION display...
  • Page 46 Error condition Error code Error description and possible diagnosis STICKING This error is displayed when a shortcircuit has been formed between the machine’s output terminals for more than 1.2 seconds. NON automatic reset error. E3.2 To remove the error state, eliminate the short circuit so that the voltage on the torch goes above the threshold value again.
  • Page 47 CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A. C.so E. Filiberto, 27 - 23900 LECCO - ITALY Cas. Post. (P.O. BOX) 205 Tel. +39 0341 22322 - Fax +39 0341 422646 cea@ceaweld.com www.ceaweld.com...

This manual is also suitable for:

Convex 401Convex 325 pulseConvex 405 pulse

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