Cea Rainbow hf series User manual

EN Operator’s manual READ CAREFULLY

RAINBOW HF

201 • 182 PRO • 202 PRO

1020HB47C-EN-03/2016 SN - ZC xxxxxx

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: [email protected] - web: www.ceaweld.com

ENGLISH

Introduction 2

Description 2

Features 2

Usage limits (IEC 60974-1) 3

Technical data 3

How to lift up the machine 3

Open the packaging 3

Serial number 3

Installation 3

Connection to the electrical supply 4

Instructions for use 4

TIG welding 4

Electrode welding (MMA) 6

Maintenance 6

Optional 6

The pointing out of any difficulties

and their elimination 7

Procedure for welder assembly and disassembly 7

Digital interface PCB replacement 7

Meaning of graphic symbols on machine 8

Wiring diagram 8

Description

RAINBOW 201 HF - 182 HF PRO - 202 HF PRO with digital control

represents the very latest evolution in direct current weld genera-

tors with INVERTER technology. This powerful 100 KHz generator,

based on the latest generation IGBT, fitted with a planar transform-

er, makes it possible to TIG weld any metal except for aluminium

and its alloys.

RAINBOW 201 HF - 182 HF PRO - 202 HF PRO, also excellent for

electrode welding, with its lightness and compactness and first-rate

welding characteristics, is ideal for using for maintenance, erec-

tion and light steel structural works.

Features

Main features are:

• Innovative and compact design.

• Compact size and light weight for easy transportation.

• Load-bearing structure with panels made of impact-resistant fi-

bre.

• Robust handle integrated into the chassis.

• Control panel protected against accidental impact.

•

Sloping front control panel, easy to read and adjust and highly

visible from any direction.

• IP 23 S protection class and dust-proof electronic components,

thanks to the innovative “Tunnel” fan cooling system, allow their

use in the toughest work environments.

• Two control panels are available:

Rainbow 201 HF with an RW21 “basic version” control panel.

Rainbow 182 HF Pro - 202 HF Pro with an RW22 “complete

version” control panel.

•

Digital control, regulation and monitoring of all welding param-

eters.

• Digital display for pre-setting welding parameters.

•

Digital ammeter is standard fittings, with pre-setting of welding

current and saving of the latest value (Hold function).

• Feature that makes it possible to save and call up personalised

welding programs (only adjustable with the RW22 control panel).

• Self-diagnosis device.

• Overheating thermostatic protection.

•

Automatic compensation for mains voltage fluctuations within

±20%.

• Safety barrier against excess voltage from mains.

•

Electromagnetic disturbance is reduced due to high frequency

being involved only during the arc ignition phase.

• “Energy Saving” function that starts ventilation of the generator

only when necessary.

•

This generator also conforms to all the standards and directives

in force in the European Community.

• TIG

- Excellent TIG welding characteristics.

High frequency arc striking of TIG welding, precise and effi-

cient even from long distance.

- Using special TIG torches allows remote adjustment of weld-

ing current directly from the torch.

Standard built-in pulsation with provision for entering the SYN

Pulse function (only adjustable with the RW22 control panel).

Introduction

Thank you for buying our product.

In order to get the best performance out of the plant and ensure the

maximum lifespan of its parts, the use and maintenance instruc-

tions contained in this manual must be read and strictly complied

with, as well as the safety instructions contained in the rele-

vant folder. If repairs to the plant are required, we recommend that

our clients contact our service centre workshops, as they have the

necessary equipment and personnel that are specifically trained

and constantly updated.

All our machines and equipment are constantly developed and so

changes may be made in terms of their construction and features.

For further information on our products or to contact CEA, go to a

CEA authorised dealer or to CEA’s website at www.ceaweld.com.

• MMA

The VRD (Voltage Reduction Device) can be activated, which

reduces voltages to below 12 V, which means that the weld-

ing machine can be used in ambient conditions in which there

is a high electrical risk, thereby providing maximum opera-

tor safety.

Arc Force to select the best dynamic characteristics of the

welding arc (only adjustable with the RW22 control panel).

Hot Start to improve ignition with particularly difficult electrodes

(only adjustable with the RW22 control panel).

- Anti-sticking function to avoid the electrodes sticking.

Usage limits (IEC 60974-1)

The use of a welder is typically discontinuous, in that it is made up

of effective work periods (welding) and rest periods (for the posi-

tioning of parts, the replacement of wire and underflushing opera-

tions etc. This welder is dimensioned to supply a I2max nominal

current in complete safety for a period of work of X% of the to-

tal usage time. The regulations in force establish the total usage

time to be 10 minutes. The work cycle is considered to be X% of

this period of time. If the permitted work cycle time is exceeded,

an overheat cut-off occurs to protect the components around the

welder from dangerous overheating. Activation of thermal protec-

tion is signaled by “t° C” flashing on control panel display (for fur-

ther information see the RW21 / RW22 control panel manual). After

several minutes the overheat cut-off rearms automatically and the

welder is ready for use again.

Technical data

The general technical data of the system are summarized in ta-

ble 1.

How to lift up the machine

The weld machine has a strong handle all in one with the frame,

used for transporting the machine manually only.

NOTE: These hoisting and transportation devices conform to Eu-

ropean standards. Do not use other hoisting and transportation

systems.

Open the packaging

Upon receiving the system:

•

Remove the welding generator and all relevant accessories-

components from their packaging.

•

Check that the weld machine is in good condition, if not report

any problems immediately to the seller-distributor.

•

Make sure all ventilation grilles are open and that no foreign bod-

ies are blocking the air circulation.

Serial number

The welding machine’s serial number is shown on the unit’s data

plate.

The serial number provides the key to tracing the production lot

applicable to the product. The serial number may be essential with

ordering spare parts or planning maintenance.

Installation

The installation site for the system must be carefully chosen in or-

der to ensure its satisfactory and safe use. The user is responsi-

ble for the installation and use of the system in accordance with

the producer’s instructions contained in this manual. Before install-

ing the system the user must take into consideration the potential

electromagnetic problems in the work area. In particular, we sug-

gest that you should avoid installing the system close to:

• Signalling, control and telephone cables.

• Radio and television transmitters and receivers.

• Computers and control and measurement instruments.

• Security and protection instruments.

Table 1

Model RAINBOW 201 HF RAINBOW 182 HF PRO RAINBOW 202 HF PRO

TIG DC MMA TIG DC MMA TIG DC MMA

Single-phase power supply 50/60 Hz V 1~230 ±20% 1~230 ±20% 1~230 ±20%

Mains supply: Zmax (*) Ω0,19 0,19 0,19

Power input @ I2Max kVA 8,5 9,0 6,9 8,3 8,5 9,0

Delayed fuse (I2@ 100%) A201620

Power factor / cosφ0,67 / 0,99 0,67 / 0,99 0,67 / 0,99

Maximum efficiency degree η0,82 0,84 0,82 0,84 0,82 0,84

Open circuit voltage V889088

Current range A 5÷200 5÷160 5÷180 5÷160 5÷200 5÷160

Duty cycle @ 100% (40°C) A 120 110 110 80 120 110

Duty cycle @ 60% (40°C) A 140 130 130 100 140 130

Duty cycle @ X% (40°C) A 200 (25%) 160 (30%) 180 (25%) 160 (20%) 200 (25%) 160 (30%)

Standards IEC 60974-1 • IEC 60974-3 • IEC 60974-10

Insulation class IP 23 S IP 23 S IP 23 S

Protection class FFF

Dimensions mm 390-300-135 390-300-135 390-300-135

Weight kg 7,5 7,5 7,5

(*) Mains supply Zmax: maximum impedance value allowed for the grid according to the EN/IEC 61000-3-11 standard.

WARNING: This equipment does not comply with EN/IEC 61000-3-12. If it is connected to a public low voltage system, it is the responsibility

of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment may

be connected.

Persons fitted with pace-makers, hearing aids and similar equip-

ment must consult their doctor before going near a machine in op-

eration. The environment in which the equipment is installed must

be suitable for the casing’s protection level. This system is cooled

by means of the forced circulation of air, and must therefore be

placed in such a way that the air may be easily sucked in and ex-

pelled through the apertures made in the frame.

The welding unit is characterised by the following levels:

•

Protection level IP 23 S indicates that the equipment can be used

both indoors and outdoors.

•

Use class means that the equipment can be used in condi-

tions subject to heightened electrical shock.

Connection to the electrical supply

Before connecting the welder to the electrical supply, check

that the machine’s plate rating corresponds to the supply volt-

age and frequency and that the line switch of the welder is in

the “O” position.

Connection to the power supply must be carried out using the trip-

olar cable supplied with the system, of which:

•

2 conducting wires are needed for connecting the machine to

the supply.

• The third, which is YELLOW GREEN in colour is used for mak-

ing the “EARTH” connection.

Connect a suitable load of normalised plug (2P + e) to the

power cable and provide for an electrical socket complete

with fuses or an automatic switch. The earth terminal must

be connected to the earth conducting wire (YELLOW-GREEN)

of the supply.

Table 2 shows the recommended load values for retardant sup-

ply fuses.

NOTE 1: Any extensions to the power cable must be of a suitable

diameter, and absolutely not of a smaller diameter than the spe-

cial cable supplied with the machine.

NOTE 2: It is not advisable to plug up the welder to motor-driv-

en generators, as they are known to supply an unstable voltage.

Instructions for use

COMMAND AND CONTROL UNITS (Fig. A)

Pos. 1 RW21 / RW22 command and control panel.

Pos. 2 Positive pole quick connection.

Pos. 3 Fast coupling TIG torch gas tube.

Pos. 4 TIG weld auxiliary control connector (torch button, re-

mote controlpedal, etc.).

Pos. 5 Negative pole quick connection.

Pos. 6 Power supply switch.

In the “O” position the welder is off.

Pos. 7 Mains cable.

Pos. 8 Weld gas inlet coupling.

TIG welding

In the TIG process welding is achieved by melting the two metal

pieces to be joined, with the possible addition of material from the

outside, using an arc ignited by a tungsten electrode. The molten

bath and the electrode are protected by and inert gas (e.g. Argon,

and a flow rate of around 8-14 litres per minute). If necessary, to

complete the welded joint, suitable additional material is added.

FIG. A

Table 2

Model RAINBOW 201 HF RAINBOW 182 HF PRO RAINBOW 202 HF PRO

TIG DC MMA TIG DC MMA TIG DC MMA

Power input @ I2Max kVA 8,5 9,0 6,9 8,3 8,5 9,0

Delayed fuse (I2@ 100%) A201620

Duty cycle @ X% (40°C) A 200 (25%)* 160 (30%)* 180 (25%)* 160 (20%)* 200 (25%)* 160 (30%)*

Supply connection cable

Length

Section

mm2

2,5

Earth cable

Section mm225 25 25

* Factor of efficiency

The type of additional material and welding current are determined

according to the type of thickness of the base material, the shape

of the joint, and the position of the weld.

1) Connecting the welding cables (Fig. B):

• Connect the gas hose to the Argon cylinder.

• With the machine switched off:

Connect the ground cable to the snap-on connector

marked + (positive).

Connect the relative ground clamp to the workpiece or

to the workpiece support in an area free of rust, paint,

grease, etc..

Connect the TIG torch power cable to the snap-on con-

nector marked - (negative).

Connect the torch gas tube to the connection (Pos. 3,

Fig. A).

Insert the torch button connector in the 6 poles holder

(Pos. 4, Fig. A).

2) Switch the welding machine on by moving the power supply

switch to I(Pos. 6, Fig. A).

3) Make the adjustments and select the parameters on the con-

trol panel (for further information see the RW21 / RW22 con-

trol panel manual).

TIG WELDING WITH “Lift” TYPE STRIKING

4a) Open the gas cylinder and flow regulator (8-14 l/min).

5a) Put the electrode at the point at which welding is to begin, put

the TIG torch at an angle so that the edge of the gas nozzle

is not on top of the piece to be welded, keeping contact be-

tween the point of the electrode and the piece to be welded

(Fig. C-1).

6a) Press the torch button.

7a) The “Lift” function strikes the arc when the TIG torch electrode

comes into contact with the workpiece and is then removed

(Fig. C-2)

8a) Carry out TIG welding (Fig. C-3).

To end welding:

•

Lift the torch slowly, at a certain point the welding current

decreases, and then stop.

•

The welding machine follows an automatic down slope

along with extinguishing of the arc.

9a) When finished welding remember to shut off the gas cylinder.

TIG WELDING WITH HIGH FREQUENCY STRIKING (HF)

4b) Open the gas cylinder and flow regulator (8-14 l/min).

5b) Put the electrode at the point at which welding is to begin, put

the TIG torch at an angle so that the edge of the gas nozzle is

not on top of the piece to be welded, keeping a 2-3 mm gap

between the point of the electrode and the piece to be weld-

ed (Fig. D-1).

6b) Press the torch button.

7b) The voltaic arc strikes even without contact between the TIG

torch electrode and the workpiece (Fig. D-2).

8b) To continue welding put the torch back in its normal position

(Fig. D-3).

9b) When finished welding remember to shut off the gas cylinder.

IMPORTANT: The high frequency switches off automatically af-

ter switching on.

PART TO BE WELDED

The part to be welded must always be connected to ground in or-

der to reduce electromagnetic emission. Much attention must be

afforded so that the ground connection of the part to be welded

does not increase the risk of accident to the user or the risk of dam-

age to other electric equipment. When it is necessary to connect

the part to be welded to ground, you should make a direct con-

nection between the part and the ground shaft. In those countries

in which such a connection is not allowed, connect the part to be

welded to ground using suitable capacitors, in compliance with the

national regulations.

WELDING PARAMETERS

Table 3 shows the currents to use with the respective electrodes

for TIG welding. This input is not absolute but is for your guidance

only; read the electrode manufacturers’ instructions for a specific

choice. The diameter of the electrode to use is directly proportion-

al to the current being used for welding.

Table 3

Ø ELECTRODE (mm) CURRENT (A)

1,2

1,6

2,4

3,2

4,0

10 ÷ 80

70 ÷ 150

140 ÷ 250

225 ÷ 400

300 ÷ 500

Before use, sharpen the tungsten electrode, forming a tip about

1,5 times its diameter.

2000HA73

2000HA72

FIG. C FIG. D

FIG. B

FIG. E

If the electrode comes into contact with the work-

piece, the point must be formed again.

The point on the electrode must be shaped as

shown in the figure.

α(°) CURRENT (A)

60 ÷ 90

90 ÷ 120

0 ÷ 30

30 ÷ 120

120 ÷ 250

Electrode welding (MMA)

The welding electrode is used to weld most metals (various types

steel, etc.),for which rutilic and basic electrodes are used.

1) Connecting the welding cables (Fig. F):

Disconnect the machine from the mains power supply and con-

nect the welding cables to the output terminals (Positive and

Negative) of the welding machine, attaching them to the clamp

and ground with the polarity specified for the type of electrode

being used (Fig. F). Always follow the electrode manufactur-

er’s instructions. The welding cables must be as short as pos-

sible, they must be near to one another, positioned at or near

floor level. Do not touch the electrode clamp and the ground

clamp simultaneously.

2) Switch the welding machine on by moving the power supply

switch to I(Pos. 6, Fig. A).

3) Make the adjustments and select the parameters on the con-

trol panel (for further information see the RW21 / RW22 con-

trol panel manual).

4) Carry out welding by moving the torch to the workpiece. Strike

the arc (press the electrode quickly against the metal and then

lift it) to melt the electrode, the coating of which forms a protec-

tive residue. Then continue welding by moving the electrode

from left to right, inclining it by about 60° compared with the

metal in relation to the direction of welding.