multi wave manual

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Manuale Istruzione IT Multi Synergic 250 - Multi Synergic 380 - Multi Synergic 500 and Accessories

Multi Wave 200 AC/DC - Multi Wave 400W AC/DC - Multi Wave 500W AC/DC Multi Wave 250 DC - Multi Wave 400W DC AND Accessories

This manual must be completed by the CE Operating and service maual Edition of 23/04/2012 Rev.04

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Instruction Manual Multi Wave 200 AC/DC - Multi Wave 400W AC/DC - Multi Wave 500W AC/DC - Multi Wave 250 DC - Multi Wave 400W DC and Accessories

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WARNINGIMPORTANT: BEFORE STARTING THE EQUIPMENT, READ THE CONTENTS OF THIS MANUAL, WHICH MUST BE STORED IN A PLACE FAMILIAR TO ALLUSERS FOR THE ENTIRE OPERATIVE LIFE-SPAN OF THE MACHINE.THIS EQUIPMENT MUST BE USED SOLELY FOR CUTTING OPERATIONS.

INTRODUCTIONTo obtain the best performance from the machine and ensure the longest possible life of all its components you must careffully follow the instructions for use and maintenance detailed in this manual. In the interest of our customers we suggest any maintenance or repair of the equipment is made by qualified personnel. All our products are subject to a constant development. We are therefore constrained to reserve the right to make any necessary or useful changes in design and equipment.

ROUTINE MAINTENANCEPrevent metal powder from accumulating inside the equipment. Disconnect the power supply before every operation ! Carry out the following periodic controls on the power source:

Clean the power source inside by means of low-pressure compressed air and soft bristel brushes. Check the electric connections and all the connection cables.For the use and maintenance of the pressure reducers, consult the specific manuals.

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1. DECLARATION OF CONFORMITY

TER SRL - Via Leopardi, 13 - 36030 Caldogno (VI) Italydeclares that the machines descripted in this manual must be use solely for professional purposes in an industrial environment and they are manufactured in compliance with the instructions contained in the harmonized standard:2006/95/CE (LDV) 2004/108/CE (EMC) 2002/95 (RoHs)and with the instructions contained in the harmonized standard,if applicable: EN 60974-1 EN 60974-2 EN 60974-3 EN 60974-5 EN 60974-7 EN 60974-10 EN 60974-12

Maurizio Terzo Direttor Generale Date 23/01/2012

IN CASE OF ANY TECHNICAL PROBLEM ASK FOR QUALIFIED SERVICE ASSISTANCE

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The equipment dont compiles with EN/ IEC 61000-3-12. The installer or the user must be sure that it can be connected to the public low voltage power line, if necessary, in consultation with the network distributor.

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2. RAEE STANDARDSThe symbol on the product or on its packaging indicates that this product may not be treated as household waste. Instead it shall be handed over to the applicable collection point for the recycling of electrical and electronic equipment. By ensuring this product is disposed of correctly, you will help

prevent potential negative consequences for the environment and human health, which could otherwise be caused by inappropiate waste handling of this product. For more detailed information about recycling of this product, please contact your local city office, your household waste disposal service or the shop where you purchased the product.

3. SAFETY PRECAUTIONSWELDING AND ARC CUTTING CAN BE HARMFUL TO YOURSELF AND OTHERS. The user must therefore be educated against the hazards, summarized below, de-riving from welding operations.

RISK of FIRE and BURNSSparks (sprays) may cause fires and burn the skin; you should therefore make sure there are no flammable materials in the area, and wear ap-propriate protective garments.

NOISEThis machine does not directly produce noise exceeding 80dB. The plasma cutting/welding procedure may produce noise levels beyond said limit; users must therefore implement all precautions required by law.

PACE MAKERThe magnetic fields created by high currents may affect the operation of pacemakers. Wearers of vital electronic equipment (pacemakers) should consult their physician before beginning any arc welding, cut-ting, gouging or spot welding operations.

EXPLOSIONSDo not weld in the vicinity of containers under pressure, or in the pres-ence of explosive dust, gases or fumes. All cylinders and pressure regu-lators used in welding operation should be handled with care.

ELECTRIC SHOCK May be fatalInstall and earth the welding machine according to the applicable regu-lations. Do not touch live electrical parts or eletrodes with bare skin, gloves or wet clothing.Isolate yourselves from both the earth and the workpiece. Make sure your working position is safe.

FUME and GASES May be hazardous to your healthKeep your head away from fumes. Work in the presence of adequate ven-tilation, and use ventilators around the arc to prevent gases from forming in the work area.

ARC RAYS May injure the eyes and burn the skinProtect yuor eyes with welding masks fitted with filtered lenses, and protect your body with appropiate safety garments.Protect others by installing adequate shields or curtains.

4. GENERAL DESCRIPTIONThis machine is a constant direct current power source, designed for welding electrically conductive materials (metals and alloys) using the electical arc procedure.

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WIRE FEEDER SUPPORT

TORCH SUPPORT

CABLE SUPPORT

INTERCONNECTINGCABLE SUPPORT

MECHANICAL ACCESSORIES

MANUAL REMOTE CONTROLFOR MMA AND TIG

FOOT REMOTE CONTROLFOR TIG APPLICATIONS

DRC - DIGITAL REMOTECONTROL FOR AC/DCAND DC TIG REMOTEAPPLICATIONS

REMOTE TORCH WITHADJUSTMENT AND JOGCONTROL

DRC - DIGITAL REMOTECONTROL FOR AUTOMATICAPPLICATIONS

REMOTE CONTROL ACCESSORIES

V0090AA V0015AA

V0031AAV0100AA

V0110AA

COLD WIRE TORCH HEAVY DUTY COLD WIRETORCH

INTERCONNECTINGCABLES

Z0244AAZ0245AA

COLD WIRE FEEDER MIG MAG PULS MIG PLUSCONCEPT WIRE FEEDERV0099AA

V0098AA

Z0083AA

APPLICATION EXPANSIONS

MULTI WAVE ACCESSORIES

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Description MULTI WAVE 200 AC/DC Power supply (+15% / -15%) V 230 1 Ph Fuses(Tig) A T25 Rated duty cycle in 10 min 40 C 40% ED Rated secondary currentA 200 Permanent sec. current 100%A 125Rated Power (Stick)KVA 5,4 Permanent power 100% (Stick) KVA 3,1 Permanent power (Tig)KVA 3,1Overload protection Thermal Frequency TIG AC mode Hz 20 200 No load voltage (S) (K) V 102 Max secondary current A 200Short circuit limit A 220 Stick electrode possibility mm 3,25Regulation field in STICK modeA 20 160Regulation field in TIG DC mode A 5 200 Regulation field in TIG AC mode A 10 200

Description MULTI WAVE 200 AC/DC Regulation field in MIG-MAG A NO Regulation field in COLD WIRE mode A 10 200 Regulation field with remote control A 5 200 Balance TIG AC mode % 10 90Protection class Ip 21Insulation class HHot Start OKAnti Sticking OK Arc Force OK Tig ignition Tig HF or Lift Arc Remote control receptacle AnalogVRD Voltage reduction device 20V OK. Water cooling unit NO Gas botthe trolley NO Width-Height-Length mm 310 x 430 x 550 Weight Kg 18

BASIC MULTI WAVE 200 AC/DC

V0095AA

MULTI WAVE 200AC/DC Digital Tig AC/DC for single phase 230V ac applications.It is light and easy to use for any applications, and helps also the unskilled welders to reach exceptional results with a self learning user interface. All the innovations of the Multi wave family are built in this portable machine with the result of higher thickness of welding material at faster speed also with single phase power supply.The functions of softness and self regulating frequency give the softer arc with the lower noise emission.The new function Asymmetrical Balance Control and Mix Arc allows the use with light Tig torches and lower tung-sten electrode size also with high current and heavy ap-plications.

Description MULTI WAVE400W AC/DC Power supply (+15% / -15%) V 400 3 PhFuses(Tig) A T25Rated duty cycle in 10 min 40 C 40% EDRated secondary current A 400Permanent sec. current 100% A 250Rated Power (Stick) KVA 11Permanent power 100% (Stick) KVA 9Permanent power (Tig)KVA -Overload protection ThermalBalance TIG AC mode % 10 90Frequency TIG AC mode Hz 20 200No load voltage (S) (K) V 92Max secondary current A 400Short circuit limit A 450Stick electrode possibility mm 6,0Regulation field in STICK mode A 20 250Regulation field in TIG DC mode A 5 400 Regulation field in TIG AC mode A 12 400Regulation field in MIG-MAG A 10 320Regulation field in COLD WIRE mode A 5 400Regulation field with remote control A 5 400

Description MULTI WAVE400W AC/DC Protection class Ip 21-SInsulation class HHot Start OKAnti Sticking OKArc Force OKTig ignition HF or Lift Arc Remote control receptacle Analog and digitalVRD Voltage reduction device 20V OK. Water cooling unit Built inGas botthe trolley Built inWidth-Height-Length mm 310 x 1000x 1000 Weight Kg 65

V0096AA

MULTI WAVE 400W AC/DCHigh power 400A AC/DC Multifunction with the latest innovation of the Multi wave family. With its 400A, 40% duty cycle is ideal for Industrial nobel metal fabrications. It is completed with :

-Stick electrode features at DC-E+, DC-E- and AC with auto-change of welding polarity and synergic direct thickness adjustment.-TIG AC/DC with the innovative Multi Wave approach with the latest innovations that grant improvement in the quality and carry the re-sults to the highest level with the minimum effort. The base power source includes the water cooling built-in and can be used both in TIG and MIG-MAG. Wide range of accesso-ries allows the upgrading of the machine to the advanced automatic TIG COLD WIRE as well as to the synergic MIG-MAG and Puls Mig with the technology of Plus Concept.

BASIC MULTI WAVE 400W AC/DC

MAIN FEATURES MULTI WAVE 200 AC/DC MAIN FEATURES MULTI WAVE 400 AC/DC

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Complete version that includes all the applications :Complete stick electrode DC-E+, DC-E- and AC with auto-change of welding polarity and synergic direct thickness adjustment. TIG AC/DC with the innovative Multi Wave approach with the latest innovations that grant improvement in the quality and carry the results to the highest level with the minimum effort. Cold wire System, fully integrated for both manual and automatic welding, the easier way to increase the efficiency

of the welding up to a reduction of the cost close to the conventional Mig welding. Mig-Mag and Puls Mig with double pulsation to complete the welding where the Tig AC/DC cannot arrive with the innovative PLUS CONCEPT. The selection between TIG AC or DC and Mig is done by simply pushing the switch of the relative torch, no other operation are necessary to start the second process as change of polarity, or gas or other adjustment. This version of equipment is completed with:Multi Wave 400W AC/DC - Water cooling unit - Interconecting to the cold wire feeder - Multi Wave cold wire feeder - Interconnecting cable 5 meters - Wire feeder support - Multifil wire feeder. The Mig and Tig

torches arent included and can be chosen from a wide variety of models standard or digital.

COMPOSITION 3

COMPOSITION 2

V0114AA

COMPOSITION 1

V0115AA

In this version the Multi wave 400W can be used also with the external wire feeder, which permits the ap-plications in Mig_Mag manual or Synergic. The plus concept version is used in this application and gives all the features of high speed and high deposit typical of the new technology.In the PULS CONCEPT Mig-Mag process also includes 4 more used Pulsed mig programs with double

pulse capability for applications in aluminium, stain-less steel, mild steel and silicon bronze. Water cooled heavy duty and air cooled torches with digital control can be chosen to complete the equipment. The selec-tion between TIG AC or DC and Mig is done by sim-ply pushing the switch of the relative torch, no other operation are necessary to start the second process as change of polarity, or gas or other adjustment.This version of equipment includes: Multi Wave 400W AC/DC - Water cooling unit - In-terconnecting cable 5 meters - Wire feeder support - Multifil wire feeder.

The power source is completed with the Multi Wave Cold Wire Feeder and its interconnecting cable. With this complete equipment the highly sophisticated Tig Cold wire can be achieved immediately thanks to the fully integrated digital cycle. Manual or automatic ad-justment is possible with a synergic regulation that adjust automatically the optimal cycles and relative values of the wire feeding also in the welding automa-tions. Shortcut and preset jobs are available to set up the system for manual or automatic Tig cold wire welding.This version of Multi Wave 400 AC/DC includes: Multi Wave 400W AC/DC - Water cooling unit - Interconnecting to the cold wire feeder - Multi Wave cold - wire feeder, The Tig Torch water cooled isnt included, and can be chosen between the ultralight supercooled 320A, the heavy duty 500A or complete kit for automatic applications.

MULTI WAVE 400W AC/DC DUO

MULTI WAVE 400W AC/DC COLD WIRE

MULTI WAVE 400W AC/DC DUOCOLD WIRE

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Description MULTI WAVE 500W AC/DCPower supply 400 3 PhFuses(Tig) A T25Rated duty cycle in 10 min 40 C 40% EDRated secondary currentA 500Permanent sec. current 100% A 320Rated Power (Stick) KVA 21Permanent power 100% (Stick) KVA 14,3Permanent power (Tig)KVA -Overload protection ThermalFrequency TIG AC mode Hz 20 200No load voltage (S) (K) V 92Max secondary current A 500Short circuit limit A 550Stick electrode possibility mm 6,0Regulation field in STICK mode A 20 320Regulation field in TIG DC mode A 5 500Regulation field in TIG AC mode A 12 500Regulation field in MIG-MAG A 10 400

BASIC MULTI WAVE500W AC/DC

V0097AA

Description MULTI WAVE 500W AC/DCRegulation field in COLD WIRE mode A 5 500Regulation field with remote control A 5 500Balance TIG AC mode % 10 90Protection class Ip 21-SInsulation class HHot Start OKAnti Sticking OKArc Force OKTig ignition HF or Lift ArcRemote control Analog and digitalVRD Voltage reduction device 20V OK.Water cooling unit Built inGas botthe trolley Built inWidth-Height-Length mm 310 x 1100x 1000Weight Kg 85

High power 500A AC/DC Multifunction with the latest innovation of the Multi wave family. With its 500A, 40% duty cycle is ideal for Industrial nobel metal fabrications in heavy applications. It is completed with :-Stick electrode features at DC-E+, DC-E- and AC with auto-change of welding polarity and synergic direct thickness adjustment.

-TIG AC/DC with the innovative Multi Wave ap-proach with the latest innovations that grant improve-ment in the quality and carry the results to the highest level with the minimum effort. The base power source includes the water cooling built-in and can be used both in TIG and MIG-MAG. Wide range of accessories allows the upgrading of the machine to the advanced automatic TIG COLD WIRE as well as to the synergic MIG-MAGand Puls Mig with the technology of Plus Concept.

COMPOSITION 1

V0118AA

In this version the Multi wave 500W can be used also with the external wire feeder, which permits the applications in Mig_Mag manual or Synergic. The plus concept version is used in this application and give all the features of High speed and high deposit typical of the new technology.In the PULS CONCEPT Mig-Mag process also includes the 4 more used Pulsed mig programs with

double pulse capability for applications in alumini-um, stainless steel, mild steel and silicon bronze. Water cooled heavy duty and air cooled torches with digital control can be chosen to complete the equipment. The selection between TIG AC or DC and Mig is done by simply pushing the switch of the relative torch, no other operation are necessary to start the second process as change of polarity, or gas or other adjustment. This version of equipment includes: Multi Wave 500W AC/DC - Water cooling unit - Interconnecting cable 5 meters - Wire feeder support - Multifil wire feeder.

COMPOSITION 2

V00117AA

The power source is completed with the Multi Wave Cold Wire Feeder and its interconnecting cable. With this complete equipment the highly sophisticated Tig Cold wire can be achieved immediately thanks to the fully integrated digital cycle, high deposit welding is possible also in TIG with improved quality and speed closed to the conventional MIG method. Manual or au-tomatic adjustment is possible with a synergic regula-tion that adjusts automatically the optimal cycles and relative values of the wire feeding also in the welding automations. Shortcut and preset jobs are available to set up the system for manual or automatic Tig cold wire welding. This version of Multi Wave 500 AC/DC includes:Multi Wave 500W AC/DC - Water cooling unit - Interconnecting to the cold wire feeder - Multi Wave cold wire feeder. The Tig Torch water cooled isnt included, and can be chosen between the ultra-light supercooled 320A, the heavy duty 500A or complete kit for automatic applications.

MAIN FEATURES MULTI WAVE 500W AC/DCMULTI WAVE 500W AC/DC DUO

MULTI WAVE 500W AC/DC COLD WIRE

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COMPOSITION 3V0119AA

Complete version that includes all the applications:complete stick electrode DC-E+, DC-E- and AC with auto-change of welding polarity and synergic direct thickness adjustment. TIG AC/DC with the innovative Multi Wave approach with the latest innovations that grant improvement in the quality and carry the results to the highest level with the minimum effort. Cold wire System, fully integrated for both manual and automatic welding, the easier way to increase the efficiency of the welding up to a reduction of the cost close to the conventional Mig welding. Mig-Mag

and Puls Mig with double pulsation to complete the welding where the Tig AC/DC cannot arrive with the innovative PLUS CONCEPT. The selection between TIG AC or DC and Mig is done by simply pushing the switch of the relative torch, no other operation are necessary to start the second process as change of polarity, or gas or other adjustment.This version of equipment is completed with:Multi Wave 500W AC/DC - Water cooling unit - Inter-connecting to the cold wire feeder - Multi Wave cold wire feeder - Interconnecting cable 5 meters - Wire feeder support - Multifil wire feeder. The Mig and Tig

torches arent included and can be chosen from a wide variety of models standard or digital.

MULTI WAVE 250 DCPortable digital Tig DC for three phase 400V ac applications. The equipment is rated at high duty cycle 250A at

Description MULTI WAVE 250 DC Power supply (+15% / -15%) V 400 3 Ph Fuses (Tig) A T16Rated duty cycle in 10 min 40C 100% ED Rated secondary current A 250 Permanent sec. current 100% A 250Rated Power (Stick) KVA 10 Permanent power 100% (Stick) KVA 10Permanent power (Tig) KVA 6,5Overload protection Thermal No load voltage (S) (K) V 92 Max secondary current A 280 Short circuit limit A 300 Stick electrode possibility mm 6 Regulation field in STICKmode A 20 220 Regulation field in TIG DCmode TIG DC A 5 250 Regulation field in MIG-MAG mode A NO

23

BASIC MULTI WAVE250 DC

V0093AA

Description MULTI WAVE 250 DC Regulation field in COLD WIREmode A 10 250 Regulation field with remote control A 5 250Protection class Ip 21S Insulation class H Hot Start OK Anti Sticking OK Arc Force OK Tig ignition Tig HF or Lift Arc Remote control receptacle Analog & digitalVRD Voltage reduction device 20V OK. Water cooling unit NO Gas botthe trolley NO Width-Height-Length mm 310 x 430 x 550Weight Kg 18

ED 100% to cover the main application on site also for heavy applications. It is light and easy to use for any applications, helps also the unskilled welders to reach exceptional results with a self learning user interface. The innovations of the Multi Wave family are built in in this portable machine with the result of higher thickness of welding material at faster speed also with single phase power supply. The equip-

ment is complete with all the cycles to perform profes-sional welding, Synergic adjustment helps the user to achieve the optimal results.The TAC (true average current) allows taking advan-tage of pulsation of the arc without extra regulation and the special function of MIX ARC helps to lift up the impurity from the welding pool in high current ap-plications.The equipment have as options the external cold wire feeder in the version air cooled for Mild steel and stainless steel applications as digital remote control and a large variety of torches.

MULTI WAVE 500W AC/DC DUO COLD WIRE MAIN FEATURES MULTI WAVE 250 DC

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Description MULTI WAVE 400W DCPower supply (+15% / -15%) V 400 3 PhFuses (Tig) A T16Rated duty cycle in 10 min 40C 40% EDRated secondary current A 400Permanent sec. current 100% A 250Rated Power (Stick) KVA 11Permanent power 100% (Stick) KVA 9Permanent power (Tig) KVA 6,5Overload protection ThermalShort circuit limit A 450Stick electrode possibility mm 6,0Regulation field in STICK mode A 20 250Regulation field in TIG DC mode TIG DC A 5 400Regulation field in MIG-MAG mode A 10 320Regulation field in COLD WIRE mode A 5 400

BASIC MULTI WAVE450W DC

V0094AA

Description MULTI WAVE 400W DCRegulation field with remote control A 5 400No load voltage (S) (K) V 92Max secondary current A 400Protection class Ip 21-SInsulation class HHot Start OKAnti Sticking OKArc Force OKTig ignition Tig HF or Lift ArcRemote control receptacle Analog & digitalVRD Voltage reduction device 20V OK.Water cooling unit Built inGas botthe trolley Built inWidth-Height-Length mm 310 x 820x 1000Weight Kg 65

High power 400A DC Multifunction with the latest innovation of the Multi Wave family.With its 400A, 40% duty cycle is ideal for Industrial nobel metal fabrications.Is completed with : -Stick electrode features with synergic direct thickness adjustment.-TIG DC with the innovative Multi Wave approach with the latest innovations that grant improvement in the

quality and carry the results to the highest level with the minimum effort.The base power source includes the water cooling built-in and can be used both in TIG and MIG-MAG. Wide range of accessories allows the upgrading of the ma-chine to the advanced automatic TIG COLD WIRE as well as to the synergic MIG-MAG and Puls Mig with the technology of Plus Concept.

COMPOSITION 1

V0121AA

In this version the Multi wave 400W can be used also with the external wire feeder, which permits the applications in Mig_Mag manual or Synergic. The plus concept version is used in this application and

gives all the features of High speed and high deposit typical of the new technology.In the PULS CONCEPT Mig-Mag process also in-cludes the 4 more used Pulsed mig programs with double pulse capability for applications in aluminium, stainless steel, mild steel and silicon bronze. Water cooled heavy duty and air cooled torches with digital control can be chosen to complete the equipment. The selection between TIG DC and Mig is done by simply pushing the switch of the relative torch, no other operation are necessary to start the second process as change of polarity, or gas or other adjust-ment. This version of equipment includes:

Multi Wave 400W DC - Water cooling unit - Interconnecting cable 5 meters - Wire feed-

er support - Multifil wire feeder.

The power source is completed with the Multi Wave Cold Wire Feeder and its interconnecting cable. With this complete equipment the highly sophisticated Tig Cold wire can be achieved immediately thanks to the fully integrated digital cycle. Manual or automatic ad-justment is possible with a synergic regulation that adjusts automatically the optimal cycles and relative values of the wire feeding also in the welding auto-mations. Shortcut and preset jobs are available to set up the system for manual or automatic Tig cold wire welding. This version of Multi Wave 400W DC includes: Multi Wave 400W AC/DC - Water cooling unit - Interconnecting to the cold wire feeder - Multi Wave cold wire feeder. The Tig Torch water cooled isnt included, and can be chosen between the ultralight supercooled 320A, the heavy duty 500A or complete kit for automatic applications.

COMPOSITION 2

V0122AA

MAIN FEATURES MULTI WAVE 400W DC MULTI WAVE 400W DC DUO

MULTI WAVE 400W DCCOLD WIRE

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COMPOSITION 3V0123AA

Complete version that includes all the applications :Complete stick electrode with synergic direct thickness adjustment. TIG DC with the innovative Multi Wave ap-proach. Cold wire System, fully integrated for both manual and automatic welding, the easier way to increase the efficiency of the welding up to a reduction of the cost close to the conventional Mig welding. Mig-Mag and

Puls Mig with double pulsation to complete the welding where the Tig AC cannot arrive with the innovative PLUS CONCEPT.. The selection between tig DC and Mig is done by simply pushing the switch of the relative torch, no other operation are necessary to start the second pro-cess as change of polarity, or gas or other adjustment.This version of equipment is completed with:Multi Wave 400W AC/DC - Water cooling unit - Interconnecting to the cold wire feeder - Multi Wave cold wire feeder - Interconnecting cable 5 meters - Wire feed-er support - Multifil wire feeder.

The Mig and Tig torches arent included and can be cho-sen from a wide variety of models standard or digital.

MULTI WAVE 400W DC DUO COLD WIRE

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MULTI WAVE USER SETTINGS:1 Digital front panel

2 Main knob

3 Second knob

4 Tig Torch socket

5 Tig gas output

6 Torch switch socket

7 Digital remote control (DRC) socket

8 Analog remote control socket

9 Electrode cable socket

10 Work-piece cable socket

11 AC/DC 200 front view (missing DRC socket)

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ELECTRODE WELDING SYNERGIC: In Synergic the arc force, hot start and anti sticking are automatic and the range of the set is displayed in both the way, thickness of work piece and current.

ELECTRODE WELDING MANUAL:in manual the set of the current and arc force are done trough the two knobs

ELECTRODE WELDING, ALSO MMA (MANUAL METAL ARC), use constant current characteristic, with vertical set level with constant current, that start to increase when the arc voltage become lower that the optimal working point ( green line in the side plot).The Multi Wave series has a professional characteristic for MMA welding, that can give excellent results with any kind of electrode.The machines can have the function of VRD ( Voltage Reduction Device) that reduces the no load voltage down to 25V.The No load voltage of the machines in MMA mode do not give any electrical risk to the user, but when the user come in contact to both the output polarity of the machine, he can fill the output voltage and have a body reaction.This body reaction as effect of conducting the low voltage trough the body, can be dangerous if the user equilibrium is not stable, for example, when he is working in suspended platform, stairs or in position where he has the risk to fall down.Any involuntary body reaction should be very dangerous. in order to avoid any risk of electrical shock to the welder, the VRD must be set, the no load voltage become 25V, level where there aren't body of muscle involuntary reaction.The striking of the arc is little bit less efficient that when the VRD is off.

The MMA setting can have two mode, MANUAL or SYNERGIC.The manual mode is the convention setting solution with current set and Arc force set for expert welders.The Synergic mode is the innovative solution, where the set is automatic, and the welder define only the kind of electrode and the thickness of the material under welding

ELECTRODE WELDING

Instruction Manual Multi Wave 200 AC/DC - Multi Wave 400W AC/DC - Multi Wave 500W AC/DC - Multi Wave 250 DC - Multi Wave 400W DC and AccessoriesE

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AF is the acronym of ARC FORCE and includes the levels of Hot Start, Arc Force and Anti Sticking, low level of arc force are used for soft electrode as stainless steel and rutile electrodes, while high level are used for cellulosic electrodes and high efficiency electrodes.With basic electrode, or high efficiency electrodes, in vertical position or under head welding position, when the current must be low to avoid the fall down of the melted material, high level of AF are helpful to to avoid the critical shut down of the arc.With the second Knob the AF can be adjusted, only in Manual mode.In Synergic the AF level is set automatically in function of the electrode chosen and with the second knob, can be decreased or increased in % system.AF has a range from 0 to 100, at minimum the levels of hot start, arc force and anti sticking are at negligible level compared to the welding current, while at maximum level (set=100 ), the dynamic is very high up to three times the set.

The adjustment of the Arc Force is trough the second knob.The main display shows the acronym AF and the secondary display shows the current value of the AF set.

In AC MMA, the output waveform is mix SQUARE SINUS wave with balance 50% and 50 Hz

The selection of the polarity is done from the front panel without the need of moving the cable in the front socket.

The polarity of the electrode can be POSITIVE (DCEP), NEGATIVE (DCEN) or AC. (AC only for the AC/DC Multi Wave)

The dynamic of the MMA process is simplified in the next pictures, where there are the three typical MMA welding situation, Arc starting, welding and the case of arc sticking.

DYNAMIC OF THE ARC :The dynamic of the arc is controlled by the function ARC FORCE that contains tha parameters for Hot Start, Arc Force Current and Anti Sticking.


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HOT START, the current at the start is higher than the set, after the start, the current slow down to set current in 0,3 seconds

ARC FORCE, when the material is transferring to the work piece, there is an automatic increasing of the current that helps the dynamic transfer of the drop.

ANTI STICKING, if the electrode is sticked to the work piece for more than 1,2 seconds the current shut off and the electrode is preserved from burning.

In MMA, the current can be adjusted from 20A up to the maximum of the machine trough the first knob, the remote control can be used and can be connected to the remote receptacle in the front panel. In this case, trough the main knob, the maximum current is defined and displayed in the front panel during the adjustment, after a couple of seconds, the display shows the reduced current trough the remote control.The remote control, adjust the current set, from the maximum value defined with the front main knob, down to 20A.When remote control is used the icon I SET flash continuously.During the welding,the icon ISET disappear and the main display shows the real welding current and the secondary display the real welding voltage, these value stay stored after the welding.

The control store the last selection and settings and restore it when MMA process is recalled.

MMA WELDING, DYNAMIC OF THE ARC


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TIG DC welding can have the follow modality:TIG DC ManualTIG DC SynergicTIG DC PULSE ManualTIG DC PULSE SynergicTIG DC MIX ManualTIG DC MIX Synergic

THE TORCH CYCLES can be selected between:the kind of arc ignition system between Lift arc and HF startthe torch switch cycle between timer, two step, two step with slopes, 4 step and 4 step with slopes

CharacteristicV=10+0,04 x I

Set current

TIG , Tungsten Arc Welding Direct Current, is constant current with true vertical characteristic.The Multi Wave series has professional characteristic, with the full option for the most sophisticated application, but with the innovation system of the Synergy, where also complex applications can be achieved with the automatic setting.The high open loop voltage, allow good arc stability with the plasma shape of the arc typical of the high tech power sources.

JOBS ( easy access to the preset parameters):TIG DC in any selection there are 6 JOBS, any job contains all the user settingThe jobs are stored once the adjustment is done and can be moved, or copied.

THE IGNITION OF THE ARC can be selected between:Lift arc ignition ( in Multi Wave technology, the Lift arc can be used also in AC welding without affecting the arc stability)HF ignition ( special HF system is used in order to reduce to zero the electrical noise the normally is introduced in the environment by the HF)

TIG WELDING MODALITY CAN BE DC CURRENT OR AC CURRENT. AND WITHIN DC AND AC THERE ARE SUB-MODALITY

TIG WELDING, COMMON FUNCTIONS:

TIG AC welding can have the follow modality:TIG AC Manual*TIG AC Synergic*TIG AC PULSE Manual*TIG AC PULSE Synergic*TIG AC MIX Manual*TIG AC MIX Synergic**: AC functions only in the Multi Wave AC/DC

TIG WELDING


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The torch switch drive on the cycle, but the arc starts only touching the work piece with the tungsten.The system drive the power only when the electrode touch the work piece, and stay at very low value until the tungsten is lifted from the work piece.Multi wave has an high efficiency lift arc that never damage the tungsten electrode and allows a perfect and fast arc striking where high frequency starting is not allowed, as hospital, airports, power station, nuclear plants and any place where the noise emission of the high frequency can be forbidden or dangerous.Can be also a solution in off shore applications, where very long torches must be used.

High frequency starts automatically after the pre gas time, and ignite the arc after a fraction of second.A special pulse of current concentrate the current in the tip of tungsten, giving a prompt starting also at low current.The high frequency is limited in voltage and time in order to avoid electromagnetic noise to the environment and respect the limits of international norms EN 60 974-3.If the arc doesn't start within 1 second, the high frequency shut off, to restart, the torch switch must be driven again.

Push buttom

Icon HF

To switch between high frequency and lift arc, the last right side push button of the front panel must be pushed and held down for 3 seconds, after this time, the icon of HF become off and the icon of LIFT-ARC become on (or vice versa)

THE IGNITION OF THE ARC


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SELECTION OF THE TORCH CYCLE

The icon of the Cycle selected light on in the front panel, in 2T and 4T only pre gas and post gas can be adjusted, while the time can be adjusted only in timer

2 STEP 2 STEP WITH SLOPE 4 STEP 4 STEP WITH SLOPE TIMER

2 STEP: at trigger on, pre-gas, than arc starts at set current, at trigger off, the arc ends and than post gas, if during post gas the trigger is on again, the arc restart without pre-gas.2 STEP WITH SLOPE: at trigger on, pre-gas, than arc start at start current and slow down to set current with down slope time, at trigger off, the current slow down to stop current with the second down slope time and than the arc ends and than post gas....4 STEP: at switch on, the gas come out, at trigger off, the arc starts at set current, at trigger on again the arc end, the gas stops when the trigger is released again if the post gas is over, otherwise the gas flows up to the end of post gas.4 STEP WITH SLOPE: at trigger on there is the pre-gas, after it the arc starts at level I start, when the trigger is released, the current slow down to set current with the time of the first slope, at the next trigger on the current slow down to stop current with the time of second slope, the current stay at the I stop level, the current ends when the torch is released, than starts the post gas.TIMER: at trigger on the pre-gas starts, than the arc starts and ends after the time of timer expires, whatever the trigger is on or off.The start current can be higher or lower than set current ( its value is between 20 up to 200% of I set, when is the fist slope can be rising or slowing depending from it value)

ICONS OF TORCH CYCLE

RIGHT PUSH

BUTTON

Pre gas Post gas Initial current Final current Up slope down slope Timer time

When selected, the variable is indicated lighting on its icon, and in the same time the main display show an acronym of the variable, while the little display indicates the current value.With the second knob the variable can be adjusted, after the correction of the variable, the display stand to show for 1,5 seconds and that come back to display the set current

PUSH THE RIGHT SIDE PUSH BUTTON AND THE ICON SHIFT BETWEEN 2 STEP, 2 STEP WITH SLOPE, 4 STEP, 4 STEP WITH SLOPE AND TIMER.


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In Tig DC the current is stable during the welding in the preset value, the use of complex cycle as 2S and 4S allow a initial current and final current and also the first and second slope, all parameters can be adjusted in manual mode, while in Synergic mode the preset is done automatically in function of the set current.

SETTING THE SLOPES CYCLE

START level, push the forth push button, until the start icon light on end adjust the level with the second knob

FIRST SLOPE level, push again the forth pushbutton and adjust the first slope level ( seconds)

SECOND SLOPE level, push again the forth pushbutton and adjust the second slope level (seconds)

STOP level, push again the forth pushbutton and adjust the stop current level (% of the set)

POST GAS level, push again the forth push button and adjust the post gas time

PRE GAS level, push the forth push button for three seconds and when the icon light on, adjust the pre gas time If 2 STEP or 4 STEP or TIMER are selected, only the pre

gas, the post gas and the timer can be adjusted.But they are not lost if the cycle is changed.All the data can be stored in a job point pushing the first knob.NOTE , after the displayed settings, if the forth push button is pressed again, new setting are possible, as the ones of PULSE TIG, PULSE MIX or AC current.


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WHERE THE TIG PULSE IS USED?

SET CURRENT

Some applications need the pulsation of current to work at medium/high frequency to force the arc in a perfect triangular shape.

In Pulse tig the current moves during the welding between two levels.

In Pulse Tig the current follow the same cycle as standard TIG, but pulses between two value, which the lower ( background or I low) is set by the user in the second level menu (optimal value is between 40 to 60% of the main current), and the higher is calculated by the digital control in order to obtain the average current equal to the set current.The pulsation is characterized by T on and T off, the user set the frequency and the balance of T on Vs T off.

Pulse Tig DC welding

The High frequency pulsation is used at low current in order to avoid the typical movement of the arc inthe tip of the tungsten electrode.In effect in this mode the arc stay more stable and it is easier to concentrate the thin arc in the middle of the joint.In order to concentrate the arc the frequency should be adjusted from 50 up to 1000 Hz ( 1000 pulse per second)

Low current DC Tig welding Low current Pulse DC Tig welding

The current has the average effect in the welding, but during the high pulse the arc is forced to move in the point of tungsten and cannot move around as often appear, as results the emission point of the arc become very stable and the arc direction is more forced thanks to the higher plasma effect of the high pulse.


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AT HIGHER CURRENT THE LOW FREQUENCY PULSATION IS USED: It helps to synchronize the cold wire feeding, both in manual and automatic welding The aspect of the welding is well

improved with the typical form of regular wave also without the feeding cold wire, this is due to the help in the movement of the hand that is synchronized with the pulsation.

Peak pulse feed material Low pulse move the torch ahead

Cool down and close

Another important effect is with medium high current because the high energy during the peak helps to burn up the impurity that come from the work piece and from the cold feeding wire.

During the low pulse the weld bath cool down and the surface tension close the gap

The pulsation starts at the end of the first slope with its high pulsation.The down slope trigger the low pulse and the pulsation ends with the high pulse at the end of the down slope, the crater filler current stay dc as in the standard cycle

PULSATION AND SLOPES


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SETTING THE PULSE TIGThe pulse tig can be used in both, DC and AC welding When manual mode is selected, all the parameters of pulse tig can be adjusted by the user, while, in Synergic mode, all the parameters are set by the synergy control and the user don't need to adjust anything. The parameters of the Pulse Tig are : FREQUENCY, SOFTNESS, I LOW AND BALANCE.The I PEAK level is self calculated in function of the SET current, to allow an average current level equal to I SET.In Synergic Pulse Tig, the parameters of the Pulsation change automatically in function of the set current in order to have the optimal level for any current set.

Select pulse, starting from DC welding or AC welding, than select MANUAL ( only in manual all the Pulse parameters are can be adjusted)

MANUAL

Push the forth pushbutton, the icon PULS SET light on, and the display shows FrE ( as FREQUENCY), adjust with the second knob, if you push again the other parameters as post gas, I start... appear for adjusting. For the other technical parameters push again the forth switch for two seconds, for the access to the parameters: BAL ( Balance from 25% to 75%), I Lo ( low level current of pulsation in % of I set)and SOF ( SOFTNESS speed in current change)

SYNERGIC

Select pulse, starting from DC welding or AC welding, than select MANUAL ( only in manual all the Pulse parameters are can be adjusted)

With the second and third pushbutton, select the synergy curve. The levels of frequency, softness, I Low and balance are set automatically and self adapted to the set welding current.This solution give the optimal value of pulsation parameters for all the range of current.

JOBS AND STORING OF PARAMETERS:The system for pulse setting is the same in Tig DC and Tig AC, either in manual and Synergic.The PARAMETERS are stored after the setting and when from a different setting a pulse tig is recall, the parameters of the last pulse tig welding are also recalled.If there are more kind of welding with different pulse tig parameters, the jobs can be used to store up to six different settings for TIG DC session and TIG AC session.


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The user can adjust the frequency and the balance of the mix arc pulsation, while the peak of the current is self calculated in function of the size of the power source

Mix arc Tig DC is a special waveform of current that make a vibration in the melt material, with the effect to help the welding of butt joins when there is gap and in angle welding.The vibration of the arc is also used to move to the surface of the welding the impurities from the melting bath.

Mix arc Tig DC welding.

This new advanced welding process very useful in precision angle welding and in butt welding with gap.The low frequency pulsation has two applications:Low and medium current the effect of MIX ARC make a movement in the welding bath, this movement helps to close the gap between two joints.High current in deep material with cold wire, the vibration of the arc call in the surface the impurities of the melted material that come from the filled material or from the base material.The pattern of high current pulses come with a low frequency, with a repetition rate of two pattern per second, up to one pattern every two seconds.In manual mode, it is possible to set the repetition rate, the pattern frequency and the balance ( percent of time of the pattern over the period)In synergic mode, all the parameters are set automatically in function of the welding current.

MANUAL : Select MIX, starting from DC welding, than select MANUAL ( only in manual all the Pulse parameters are can be adjusted)

Push the forth push button, the MIX SET icon light on, the main display shows the acronyms Mix DC Balance BAL, adjust with the second knob the value of the little display between 80-up to 95%

Second level parameter can be adjusted, is the forth push button is pressed more than 2 seconds, after Pre gas the display shows FrE ( Frequency of mix, adjustable from 0,5 to 5 seconds

ICON MIX SET

If SYNERGIC set is used, all the mix parameters are automatically set by the controller in function of the set current, this is the faster and optimal way for testing the MIX DC.

The PARAMETERS are stored after the setting and when from a different setting a pulse tig is recall, the parameters of the last pulse tig welding are also recalled.If there are more kind of welding with different pulse tig parameters, the jobs can be used to store up to six different settings for TIG DC sessionSYNERGIC MIX DC


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AC WELDING ( valid only for Multi wave AC/DC 200-400 and 500) MAIN FEATURES

CFC allow a frequency regulation of the AC current, from minimum 20Hz up to maximum 200 Hz, the self ignition of the arc allows higher stability at any current and any frequency.The advanced control of the output AC do not need the high frequency for arc ignition during the polarity change, as normally appear in the conventional AC/DC power source.

TAC allows the set of true welding current, it compensate the kind of waveform of the AC current and give the output true current exactly the same as the set current.This kind of process allow a reliable adjustment of the current and a faster welding speed (up to 30%) compared to the conventional AC/DC welding.

FWC, allows a complete waveform control of the AC output, where square wave is used for low current and higher softness is used to decrease the force of the arc and the laud noise at high current.The modified sinus wave form allows the use of the machine in these applications developed with the conventional sinus wave, with the differences of true average current.

The balance control is very easy to set, and the efficiency of the arc re ignition allow a very high stability of the arc, welding with very low positive current time are possible without influence in the cleaning effect of the oxide.

Advanced asymmetrical balance control is possible, for example for high current level, is possible to limit the maximum positive current.The effect is a lower tungsten tip temperature and much faster welding speed.

Mix AC is an innovative welding solution for high current AC application, the welding is done with both the method, DC and AC, that are alternate in low frequency, this method improve the welding speed, slow down the tungsten tip temperature and improve the welding penetration.

NOT AVAILABLE IN MULTI WAVE 250 DC and 400 DC


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Each alternating current cycle, when plotted against time on a graph, has a shape like a wave, the wave can be sinus ( as in the picture), trapezoidal or square wave. The reversing of polarity ( +) makes it possible to weld Aluminum, Aluminum alloys, Magnesium and some other non ferrous metals (material with surface-insulating oxide).The reverse polarity breaks the surface oxide while the direct polarity melts the base metal.The effect of the direct polarity is the same as TIG DC where the tungsten electrode with negative polarity, emit the electrons trough the ionized gas that shots the workpiece with the effect to melt it and go deep under the surface. The effect of the reverse polarity is the opposite, the work piece, with its negative polarity, emit the electrons trough the ionized gas and shots the tip of tungsten.The electron going from the work piece to the tungsten tip has a large emitting area and broken the oxide.The effect in the workpiece is:During the direct polarity, the welding area is narrow in the surface and deep in penetration.During the reverse polarity, the welding are is wide in the surface and low in penetration.In parallel the effect in the tungsten tip is low temperature during direct polarity and wery high temperature in reverse polarity.

AC welding need a larger diameter of the tungsten electrode than TIG DC welding, due to the melting effect of the reverse polarity, but it means also less precision of the welding and heavy Tig torches cooled with water.Due to the fact that the main searched effect of the reverse polarity is the cleaning effect ( oxide burning ), the energy during the reverse polarity can be reduced at the minimum level enough to burn the oxide and clean the surface of the welding, for this, one of the important setting in AC welding is the BALANCE between the direct polarity and reverse polarity.

Reverse+ direct polarity

In the picture there are two different balances, in the upper waveform the balance setting is 50%, and in the bottom, the balance is 75%, the results in the welding is higher welding penetration ( also higher speed) and in the same time lower temperature of the tungsten or lower diameter tungsten can be used without the risk of melting the tip.It is important to use the right size of tungsten diameter in function of the current and of the balance used in the welding in order to avoid temperature too high than melt the tip and project tungsten drops in the welding pool.Another important parameter in the AC TIG welding is the waveform of the AC, in effect the waveform should be square Wave ( red in the second waveform ), trapezoidal or sinus wave. This kind of adjustment is called SOFTNESS.

Balance 50% and softness 10 ( sinusoidal) Balance 75% and softness 10 ( sinusoidal) Balance 75% and softness 3

EFFECT:-Narrow shape of the welding.-deeper penetration,-thin tungsten tip-faster welding speed -risk of missing cleaning effect

EFFECT:-Larger shape of the welding.-lower penetration.-larger tungsten tip.-Lower welding speed-good cleaning effect

THE MAIN CONTROLS FOR TIG AC WELDING ARE: BALANCE, SOFTNESS AND FREQUENCYTIG AC settings and effect in the arc of BALANCE



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With the variation of the softness, the time of transition between positive and negative polarity changes.Effects: low values of softness, will create a high stability of arc also on thin material and a reduction of the oxidation braking area.On the other hand, low values of softness will increase of the noise arc and cannot be used when the current become high.In the Multi Wave AC/DC power sources, the innovative TAC process allow adjustment of the softness without extra adjustment in the set current as appear in the other conventional machines.The TAC effect can be seen in the side plot, where the peak of the current rise up to compensate the sloping of the rising of the slope in the wave form.

TIG AC settings and effect in the arc of SOFTNESS

Low SOFTNESS give more arc force, the arc become narrow and go deep inside of the welding, this kind of adjustment can be chosen for low current, where the arc sound emission is not too laud, the quality of the arc is improved, but at medium current an engraved on the sides of the weld can appear.

Higher softness, up to sinus wave give a wider arc with less strength in the welding bath, the noise emission is inversely proportional to the softness level, must be preferred for medium-high current.

TIG AC settings and effect in the arc of FREQUENCY

By increasing the frequency, increases also the concentration of the arc on the tip of the tungsten making it more stable and with a narrower cone.High frequencies will create a louder arc.It is suggested to set high frequency for low current and low frequency for high current, in this mode, the arc become more concentrate for precision welding at low madium current, while at high current the ratio peak current / average current decrease down to 1 unit and the arc become softer.

LOW FREQUENCY GETS THE ARC WIDER AND SOFTER IS FOR HIGH CURRENT SETTINGS

HIGH FREQUENCY GETS THE ARC NARROW AND LAUDER IS FOR LOW CURRENT SETTINGS

The frequency adjustment is from 10 Hz ( 10 Cycles per second) to 200 Hz (200 Cycles per seconds)



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BALANCE FREQUENCY SOFTNESS

NOTE REGARDING THE TIG AC SETTINGS:The effect in the AC welding of the main parameters, Current, Balance, Softness and Frequency, as also the choice of the size of tungsten is for high skill level users, and need time to be tested for any new adjustment.This king of regulation is available in MANUAL mode when AC TIG is selected, but the Multi Wave series has the capability to use the Synergy mode, where selecting the material, and size of the welding, all the parameters are changed automatically.

Push the first push button up to the icon AC light on, the with the second push button, select MANUAL.The main display shows the set current.Adjust the main current with the main knob.

Press the forth push button, the icon Balance light on, little display shows the Balance value, adjust it with he second knob. If no other regulations occurs within one second the display come back to show the current set

Press again the forth push button, icon Frequency light on, while the main display has the acronym FrE, adjust its value with he second knob. If no other regulations occurs within one second the display come back to show the current set

Press again the forth push button, icon Softness light on, while the main display has the acronym SoF, adjust its value with he second knob. If no other regulations occurs within one second the display come back to show the current set

If the forth push button is pressed again, other function will be displayed for adjustment, in order to go back to the main videata, wait a couple of seconds or touch the main knob (left one)

MANUAL TIG AC MODE

SYNERGIC TIG AC MODE

Push the first push button to select AC, than push the second push button to select the material and than the third push button to select the size of the tungsten mounted in the Tig torch. The forth push button do not have regulations, all the setting are automatic

The main knob adjust the set current

The Icon thickness light on,It means that the value of little

display is the suggested material tickness under welding



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SETTING THE PULSE TIG IN AC MODEThe pulse tig can be as in DC mode. When manual mode is selected, all the parameters of the AC as Balance, Frequency and Softness are the ones adjusted in the Manual mode without pulse as de scripted in the previous page.The parameters of the Pulse Tig are : FrE PLS FREQUENCY, SoF PLS SOFTNESS, I Lo PLSI LOW AND BAL PLSBALANCE, to avoid any confusion with the setting of AC current, these new parameters has different acronyms and their icons are in different positions.The I PEAK level is self calculated in function of the SET current, to allow an average current level equal to I SET.In Synergic Pulse Tig AC, the parameters of the Pulsation change automatically in function of the set current in order to have the optimal level for any current set and the user don't need to adjust them.

The parameter for the AC welding, must be set in the normal mode AC, to adjust the AC Balance, Frequency and Softness the AC mode must be selected.

Push the first push button to change to mode AC PULSE, the set of the current remain the same, in effect the true average average current in Pulse mode is granted from the self calcolation of the digital process

Push the forth pushbutton to Access to the pulse frequencyThe icon Pulse Set light on andThe acronym in the main displayBecome FrE PLS, adjust the frequency with the second knob

To access to the other pulse parameters, push again and held pushed for two seconds the forth push button ( entry in the second level adjustment)

The main display shows the acronym BAL PLS, adjust with the second knob adjust the balance level between 25 to 75% (this level is the % of I lo

Push again and Acronym I Lo PLS appear, adjust the level of I low between 10 to 90% of I set.Push again and SoF PLS appear and adjust the softness between no up to 10.

Synergic Pulse TIG ACIn Synergic all the parameters are set automatically, in function of the set current and do need adjustment.Select AC, PULSE, than with the second push button, the Material and with the third push button, the diameter of the tungsten.

Manual Pulse TIG AC

The main display shows the current, while the second display suggest the thickness of the welding material, the pulse parameters change according with set current.



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Mix arc Tig AC welding.

-

-

DC AC ACDC

In MIX ARC AC MODE, the current continuously change between AC to DC with an effect to improve the speed of the welding with better penetration. It is indicate for high current where the temperature of the electrode tip is critical. The result in welding is similar to the PULSE AC welding but with stronger force in the welding bath, for this reason it is particularly indicated over thick material. The two state have the same average current, in the AC state the oxide is broken and the welding arc become wider and the surface impurity are burned out, in the dc state, the arc become narrow and goes deep inside the workpiece improving the penetration.The parameters are divided in two part:The first part is the AC waveform, that has the same parameters as AC Manual setting if MIX AC manual is used while in synergic the parameters are set automatically in function of Iset.The second part is the MIX parameter that are the Balance Mix from 10 to 90% of AC currente and frequency from 0,5 Hz to 5 Hz.

The parameter for the AC welding, must be set in the normal mode AC, to adjust the AC Balance, Frequency and Softness the AC mode must be selected.

Manual MIX TIG AC

Push the first push button to change to mode AC MIX, the set of the current remain the same, in effect the true average average current in Pulse mode is granted from the self calcolation of the digital process

Push the forth pushbutton to access to the MIX parameters.The icon MIX SET light on and the acronym in the main display become BAL , adjust the MIX BALANCE with the second knob ( Balance is the related to the DC time and 10% means 10% time DC and 90% time AC). Push again the push button and adjust the mix frequency between 0,5 Hz to 5 Hz.

Synergic MIX TIG AC

In Synergic all the parameters are set automatically, in function of the set current and do need adjustment.Select AC, and than MIX, than with the second push button, the Material and with the third push button, the diameter of the tungsten.

The main display shows the current, while the second display suggest the thickness of the welding material, the pulse parameters change according with set current.



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Special Applications:

The follow adjustments are for expert users and allow a better ignition of the arc in AC mode, with a pre heat cycle in the starting of the arc.The ignition is with positive polarity, with a defined current for a defined time, the default current is 80A and time is 0,3 seconds, if re ignition of the arc is done during the cool down temperature of the electrode, the pre heat time is reduced automatically, in function of the electrode tip temperature.

The AC positive current limit is used for Asymmetrical balance control, normally at medium-high current.This kind of adjustment allow a special waveform that at the same set current held lower electrode tip temperature and improve the penetration and the speed of the welding.When the set current is lower than the AC positive current limit, the waveform is as in the conventional Symmetrical balance control (upper wave form), but for higher current than the AC positive current limit, only the negative wave increase and compensate also the lower value of the positive wave.

From the Manual AC, push the forth push button up to the main display shows the acronym PrE GAS, push again and the acronym PrE alternated with i appear, and in the little display the data of its current.This is the PRE HEAT CURRENT in positive polatity that warm on the tip of tungsten.adjust the second knob for the new value, consider that the default value is 80A, but for some application different value can give a better results.

Push again the forth push button and the acronym change in PRE alternated with t, and in the second display its value, use again the second knob to adjust it. Consider that the default value is 0,3 seconds

AC CURRENT PRE HEAT

AC TIME PRE HEAT

AC POSITIVE CURRENT LIMIT

Push again the forth push button and the acronym change in LIM alternated with i P, and in the second display its value, use again the second knob to adjust it. Consider that the default value is the maximum current of the power source, than means that ASYMMETRICAL balance is not used.Reduce its value for different welding results and for adapting the maximum positive current to the tungsten diameter.

These special parameters are stored with all the other variables in the jobs, in this way some jobs can be set with special wave form for special applications



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MANUAL DC TIG SYNERGIC DC TIG MANUAL AC TIG SYNERGIC AC TIGPARAMETER CONDITION STD PULSE MIX STD PULSE MIX STD PULSE MIX STD PULSE MIXSynergy program 1-25 (mat.&size) NO NO NO YES YES YES NO NO NO YES YES YESTorch cycle type YES YES YES YES YES YES YES YES YES YES YES YESStart in HF or lift arc YES YES YES YES YES YES YES YES YES YES YES YESThe last current set YES YES YES YES YES YES YES YES YES YES YES YESPre gas time YES* YES* YES* YES* YES* YES* YES* YES* YES* YES* YES* YES*Start current only in 2S and 4S YES YES YES SYNERGIC SYNERGIC SYNERGIC YES YES YES SYNERGIC SYNERGIC SYNERGICFirst slope only in 2S and 4S YES YES YES SYNERGIC SYNERGIC SYNERGIC YES YES YES SYNERGIC SYNERGIC SYNERGICCrater filer slope only in 2S and 4S YES YES YES SYNERGIC SYNERGIC SYNERGIC YES YES YES SYNERGIC SYNERGIC SYNERGICFinal current only in 2S and 4S YES YES YES SYNERGIC SYNERGIC SYNERGIC YES YES YES SYNERGIC SYNERGIC SYNERGICPost gas YES YES YES SYNERGIC SYNERGIC SYNERGIC YES YES YES SYNERGIC SYNERGIC SYNERGICTimer time only in TIMER YES YES YES YES YES YES YES YES YES YES YES YESPulse balance PULSE NO YES* NO NO SYNERGIC NO NO YES* NO NO SYNERGIC NOPulse I low PULSE NO YES* NO NO SYNERGIC NO NO YES* NO NO SYNERGIC NOPulse frequency PULSE NO YES NO NO SYNERGIC NO NO YES NO NO SYNERGIC NOPulse softness PULSE NO YES* NO NO SYNERGIC NO NO YES* NO NO SYNERGIC NOMix balance DC vs pulsation time MIX NO NO YES NO NO SYNERGIC NO NO YES NO NO SYNERGICMix frequency MIX NO NO YES* NO NO SYNERGIC NO NO YES* NO NO SYNERGICAC current preheat NO NO NO NO NO NO YES YES* YES* SYNERGIC SYNERGIC SYNERGICAC time preheat NO NO NO NO NO NO YES YES* YES* SYNERGIC SYNERGIC SYNERGICAC positive current limit NO NO NO NO NO NO YES YES* YES* SYNERGIC SYNERGIC SYNERGICAC current BALANCE NO NO NO NO NO NO YES YES YES SYNERGIC SYNERGIC SYNERGICAC current FREQUENCY NO NO NO NO NO NO YES YES YES SYNERGIC SYNERGIC SYNERGICAC current SOFTNESS NO NO NO NO NO NO YES YES YES SYNERGIC SYNERGIC SYNERGICAC pulse FREQUENCY PULSE NO NO NO NO NO NO NO YES NO NO SYNERGIC NOAC pulse BALANCE PULSE NO NO NO NO NO NO NO YES* NO NO SYNERGIC NOAC pulse I_LOW PULSE NO NO NO NO NO NO NO YES* NO NO SYNERGIC NOAC Balance Mix MIX NO NO NO NO NO NO NO NO YES NO NO SYNERGICAC Frequency Mix MIX NO NO NO NO NO NO NO NO YES NO NO SYNERGIC

MODE Cold Wire YES YES YES YES YES YES YES YES YES YES YES YESStart Type Cold Wire YES YES YES YES YES YES YES YES YES YES YES YESWire Size Cold Wire YES YES YES YES YES YES YES YES YES YES YES YESSet retract Cold Wire YES YES YES YES YES YES YES YES YES YES YES YESSet speed Cold Wire YES YES YES SYNERGIC SYNERGIC SYNERGIC YES YES YES SYNERGIC SYNERGIC SYNERGIC

In this way the user only need to define the process and than adjust the welding current.Once the skill in the new modality will be achieved, the user can select the Manual mode and define by himself the parameter that he consider optimal for the specific application.The user can develop working session that contains the proper working modality for different application, than store these session into Jobs.The Job when is recalled from the user, shows the last set current, but in realty the current is the variable, that must be adjusted in function of the welding, while all the other parameters are already set and allow a quick return to the optimal user setting for the specific application.In the follow table there are the user parameters that are stored into the jobs.When the cold wire feeder is connected to the Multi Wave power source, the wire feeder transmit to the machine its setting, these settings are also stored into the jobs, when this job is recalled by the user, also the cold wire feeder setting is re-transmitted to the wire feeder without any need of extra control by the user in the cold wire setting.

USE of the JOBS: Multi Wave power sources has many working modality, and many new features for professional applications, but from the other side, the synergic operation give to the user the possibility to test different modality for the same application without the required experience because the digital control preset automatically all the parameter proportionally to the set current.


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The Multi Wave series has the capability to use the jobs for storing and recall working modality of the user.The jobs are 6 for the session DC and 6 for the session AC.To recall a Job, the main knob must be pushed and the main display show JOB LOAD, turn clock wise or reverse clock wide to select the Job, Once in the new job all the stored parameters are recalled as explained in the table below, any change done in the front panel setting, is stored in real time in the current job

HOW TO STORE AND RE CALL THE JOBS:

Push the first knob, the displays shows LoA job,while the leds that show the job light in the previous one

Turn the knob, clock wise or reverse clock wise, the led of the job numbers change, and the display also change showing the contents of the new job ( in the picture, job n5 is loaded

Once found the job, push again the knob, the new job session is displayed and also in its technical menu, all the parameters are the original of this job. From this time any change can be done and will be stored in this job.

To store a Job over a different job number, push the first encoder fort a time more than 5 seconds, up to the displays shows Sto n.x where x is the job in use ( in the picture is 5), and in the same time it propose where to store, starting from the same job number ( second picture job N 5)

Turn the knob, clock wise or reverse clock wise, the proposed position where store the job, change.Select the position and than push again the main knob.In this case the job N 1 and N 5 will be equals.

Remember that the jobs contains many technical parameters that can be changed only in the basic session TIG MANUAL, if these technical parameters need to be adjusted, sating in the same job, select the basic function TIG DC MANUAL or TIG AC MANUAL, make the correction of the technical parameters and than set again the original session.


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REMOTE CONTROLS:Two kind of remote control are available in the Multi Wave series, DTRC and DRC.

DTRC

DRC

DTRC, includes, three kind of controls: Manual Remote control for both the applications, TIG AC/DC and MMA, it is equipped with 5 meters cable, under request longer cables are available.It is equipped with strong magnet and can be hung on the steel structure.

FOOT REMORE PEDAL CONTROL, for TIG applications, equipped with 5 meters cable, it is a done with a robust and light case, with an high precision mechanism that allow an easy and repetitive adjustment during the welding.

DIGITAL TORCH CONTROL, There are two kind of torches, one air cooled for light application up to 200A and a water cooled torch for heavy duty applications.These torches has in te top a simple toggle switch that allow the adjustment up and down of the welding current.

The DTRC remote control are recognized by the machine, as they are connected to the socket. Without the need of extra adjustment in the machine (Plug and Play), the main knob of the machine, adjust the maximum current of the remote control.During the adjustment with the knob of the front pane, the display shows the maximum set current from the remote control, after 2 seconds the dysplay shows the set from the remote control

RDC includes two kind of digital remote controller:, DRC is the standard digital remote control and is inserted in a robust metallic frame with a strong magnet in the back and can be hung in the steel frame near the welding area.With this remote control, all the adjustment can be done far from the machine, including the job selections and parameters.The welder,, do not need anymore to go back to the front panel for setting, or adjusting, also the change of working modality and polarity is done directly from the DRC.In the mean time, the front panel repeat the setting and the choice from the DRC.DRC for AUTOMATIC APPLICATIONS, consist in a digital panel that can be inserted in the control of the mechanical automation where the Multi Wave is connected.It allows all the interface and synchronization with the welding movement controls, with a quick and easy to use set of connections ready for the simple and complex application.The DRC System is a PLUG and PLAY system and do not need extra adjustment from the user.MORE INFORMATION OVER DRC IN ITS INSTRUCTION MANUAL

NOTE FOR DRC CONNECTIONS:The Multi Wave 200AC/DC, do not have the front panel socket for RDC connection, when this is requested, a kit with easy installation can be used to have the DRC socket in the back side of the machine.When the power source is connected to the cold wire feeder, the DRC can be only connected in the Cold Wire Feeder and not in the machine ( the socket for Cold Wire Feeder is the same of DRC)


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COLD WIRE FEEDER:

MANUAL APPLICATIONS:The Cold wire Tig Torch is connected to the wire feeder trough a standard Binzel connector for the wire, while for the power, the torch is connected directly to the front power socket of the machine.The feeding of the wire is automatic, with a synchronization with the welding current, or manual driven with the same torch switch of the Tig torch, allowing a simple use in any manual applications.

MECHANIZED APPLICATIONS:The applications in automatic, mechanized welding is also easy. With the automatic settings, all the current cycle parameters of the machine are synchronized with the feeding of the wire, and the amount of the wire is self calculated by the processor, in function of the diameter of the wire and of the welding current, when the Tig cycle is pulsing, also the wire can be selected in pulse mode, with a function, of push and retract, that simulate the operator manual feeding of the filled material in the welding pool.

The front panel of the cold wire feeder, has integrated all the function in order to select from the simple up to the complex applications in automatic welding.The front panel become also a remote control of the Multi Wave machine where is connected, it means that also the welding current parameters can be adjusted directly from this panel, and up to six jobs, harmonized with the wire feeding setting can be stored and recalled from the front panel.

The Multi Wave series has the capability to control the process of TIG Cold Wire Feeder. The wire feeder is connected to the DRC receptacle in the front panel.

The Cold Wire Feeder, works as Plug and Play peripheral, once connected, the machine recognize its presence and start to implement the process of cold wire in the tig welding. The Cold wire Feeder is synchronized with the tig cycle and is fully digitally controlled.All the parameters can be chosen with manual or synergic set, in synergic, is enough the selection of the wire diameter, and the selection of the synergic process in the front panel of machine, the user define only the modality between pulsed feeding ire or

continuously feeding, and the amount, the starting, the stopping and the retract of the wire is handled automatically by the central process.


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1 Missing water in the tank fill the tank of water with anti freezing if there is low temperature environment usage

2 Pump locked for long inactivity Help the starting of the pump with screw driver as label in the left side panel

3 Air in the water pipes and inside the pump

Use the bridges in both the in/out fittings front and back side, disconnect the red fitting from the front return quick connector, start the pump pressing the trigger, wait up to the water start to come out from the front pipe. May be the alarm occurs many again, switch off and than on,the power source and repeat the operation up to the water start to circulate.

4 Locked circulation in the Mig-Mag side (rear output-input) or in the Tig side, (front output-input)

Use the bridges in the back side quick connector, and check if the water circulate (cause in the back side closed connection), or use the bridge in the front connector, and check if the water circulate ( cause of the front side closed connection)

5 Circulation sensor, broken or with a wrong setting

If the water circulate, but alarm occurs, call the service center for controls over the flow switch sensor.

The water cooling unit is an accessory of the Multi Wave series and can be easily connected.It is a box that contains the stainless steel water tank with a capacity of 4 liters and is developed for both the applications, in TIG and in MIG-MAG.

The wells must be mounted in the bottom of the water cooling box instead than in the bottom of the power source.The power source in than mounted over the water cooling unit.In the front right upper side of the water cooling unit and in the front right bottom side of the power sources, there are the two connector that must be joined together.

The water cooling unit has both the connections, for TIG, they are located in the front and for MIG_MAG in the back side ( connections to the interconnecting cable of the MIG_MAG wire feeder.

When TIG or MIG_MAG session, use a air cooled torch instead a water cooled, a pipe bridge must be used in the output that gets the circulation of the water also when the torch is not connected.The pipe bridges are included in the accessories of the water cooling unit.

PLUG & PLAY This unit is a Plug and Play peripheral and is recognized by the central processor, when is connected.

Water cooling Unit:

The water cooling unit is driven to make the water circulation only when the cycle Mig-Mag or tig is driven by the relative torch switches and stops at the end of the welding. after a cool down time that is calculated by the processor in function of the welding current and welding time.The Missing water and missing circulation of the water give a stops of the welding with an alarm in the front panel of the Multi wave machine.To reset the alarm, the power source must be switched off and when the front display is completely off, switch on again the main switch of the machine.There are the follow reason for missing water circulation:

NOT AVAILABLE IN MULTI WAVE 200AC/DC


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NOT AVAILABLE IN MULTI WAVE 200AC/DC

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1) The wire feeder available for Multi wave family is the digital Multifil wire feeder, also used in the Multi Synergic family (refer to its manual for instruction in the use)2) In the back side of the machine there are the socket for interconnecting cables, the cables are the standard as Plus Concept and Multi Synergic series and can be supplied with length up to 50 meters.3) Interconnecting cable support can be added for stable support of the cable in the back side of machine 4) Wire feeder support can be added to use the wire feeder in the top of machine

PLUG & PLAYThis unit is a Plug and Play peripheral and is recognized by the central processor, when is connected, ( start to work without any ini

Wire feeder allow welding in:MIG-MAG MANUAL ( conventional mode) SYNERGIC MODE with full program set of wire diameters from 0,8 mm up to 1,6 mm and full material set, SG2, Stainless steel. Aluminum MG, and Aluminum Si, Copper aluminum wire and flux core. PULS MIG MODE and DOUBLE PULSE MIG MODE with 5 programs most frequently used, for Mild steel, Aluminum Mg, Aluminum Si, Stainless steel and Copper alloy ( only one size of wire for any material).MMA MODE.The wire feeder has also the capability to use the digital torch for remote jobs handling or remote continuously welding parameters adjustment. To pass from Tig welding, to mig or puls mig, is enough to press the torch switch of the relative process ( Tig or Mig), the output polarity is automatically change, as the welding session, that goes to the latest used in this process.

MIG-MAG- PULS MIG EXPANSION:The power sources of Multi Wave family are expandable to MIG-MAG and PULSE MIG applications.


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MULTI WAVE WATER COOLER SPARE PARTS

N CODE DESCRIPTION RIF. WEL.DIAGRAM0 N-40-160910-11-00 WATER SPEED-PASS ACCESS BLOCK RED -1 R-38-107080-01-00 EXTERNAL WATER PIPE BYPASS -2 N-40-160910-10-00 WATER SPEED-PASS ACCESS BLOCK BLUE 3 N-37-120522-01-00 FAN FAN14 N-40-160910-11-00 WATER SPEED-PASS ACCESS BLOCK RED -5 R-24-031200-13-A0 PLASTIC PLUG -6 R-24-032200-07-A0 90PLASTIC ELBOW -7 R-37-310000-01-00 WATER-PUMP PUMP18 R-37-340000-01-00 HEAT EXCHANGER DEVICE -9 R-38-107080-01-00 EXTERNAL WATER PIPE BYPASS -10 N-40-160910-10-00 WATER SPEED-PASS ACCESS BLOCK BLUE -11 R-37-320000-04-00 WATER CONTAINER -12 R-06-030001-02-00 FLOW SENSORS FLUX1

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WATER COOLER DIAGRAM

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FILE: SHEET: 01 OF 01REV: 2No part of this document may be copied or reproduced without the prior written consent of

TITLE: TER S.r.l.Via G.Leopardi, 1336030 Caldogno(VI) ITALY

TER S.r.l.V_COOLER-UNIT-MULTISYNERGIC_V2.Sch

COOLER-UNIT-MULTISYNERGIC 21/02/2012DATE:A4

PUMP PUMP1.FAN1

.

FLUX1

.

T FASE

RELE COOLER

COOLER UNIT

-16

-15

-16

-15-16

-15

PE

PE TO COOLER UNIT17 18

51

4 7

6X1

COOLER UNIT MALE CONNECTOR

Date: 21/02/2012 Date Last Update: 20/02/2012 Version:0 Title : unit cooler cabling

Disegnatore: FRANCO VOLTOLINI E-Mail: [email protected]

TER s.r.lvia G. Leopardi, 13 36030 CALDOGNO (VI) -ITALIA-

Tel. ++39 0444 586440 Fax ++39 0444 905764http://www.terwelding.com E-MAIL: [email protected]

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N CODE DESCRIPTION RIF. WEL.DIAGRAM1 Main Switch 16A 230V Sw1 2 Emc Board Pcb1 3 Capacitor Board (Gc-Pz01-058) Pcb24 Power Board (Gc-Pm57) Pcb35 Control Board (T234) Pcb46 Output Probe Filter (T237) Pcb57 N-51-Tr-T212-A Digital Display Control Pcb68 Torch Switch Filter Phd-10 Pcb79 Remote Control Filter Phd-10 Pcb810 Gas Valve Ev1 11 N-39-106309-01-A0 Input Programming Serial Port X4012 Fan 24V DC Fan113 R-06-010000-10-00 Hall Probe Hall114 Fast Socket Dinse X45, X4815 Fan Grig Protection 16 R-23-030300-01-A0 polycarbonate Panel Protection 17 R-37-231410-05-01 Knob 18 Input Torch Switch Connector X4719 Input Remote Control Connector X4620 Power Board Yf-11009 Pcb921 R-32-101004-227-A0 Sticker Over The Digital Display Control Board

Spare Parts MULTI WAVE 200 AC/DC

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Instruction Manual Multi Wave 200 AC/DC - Multi W

multi wave manual

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