Cloos GL 502 Guide

operating instructions
and spare parts
GL 502
01/15 Rev.0
- EN -

Carl Cloos Schweisstechnik GmbH
Industriestrasse
35708 Haiger
Germany
Telefon [phone]
Telefax (0 27 73) 85-275
E-Mail: [email protected]
Internet: http://www.cloos.de
RW - FP - Rev.0
Ausgabedatum 3. 02 2015
Keep for further use.

CARL CLOOS Schweisstechnik GmbH
Industriestrasse
35708 Haiger
Tel.[phone]
Fax.[phone]
mail: [email protected]
www.cloos.de
Document: QIGLW502 Month/Year: 10/14
EC-Declaration of Conformity
in accordance with EC Directives 2006/95/EG (low voltage) and 2004/108/EG (EMV)
Designation of the machine: TIG welding machine
Type: QINEO GLW 502
Serial number: see type plate (on the rear of the machine)
The following EC Directives have been applied:
- EC Low voltage directives (2006/95/EG)
- EC Directives on Electromagnetic compatibility (2004/108/EG)
- EC Directives RoHS (2011/65/EU)
The following harmonised standards have been applied:
- EN 60974-1 Arc welding equipment
Part 1: Welding power sources
- EN 60974-3 Arc welding equipment
Teil 3: Arc striking and stabilizing devices
- EN 60974-10 Arc welding equipment
Part 10: Electromagnetic compatibility (EMC) requirements
Manufacturer's signature: Gerald Mies
Information on the signatory: Managing Director
We herewith certify that the welding machine mentioned below has been developed, designed and
manufactured in accordance with the EC Directives and brought on the market.
Any significant modifications or extensions on the machine which are not carried out by the above
manufacturer or hins authorised representative will invalidate this Declaration of Conformity.

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CONTENTS
1INTRODUCTION ............................................................................................................................................... 4
2INSTALLATION ................................................................................................................................................ 5
2.1 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK........................................................................... 5
2.2 FRONT PANEL.................................................................................................................................................. 5
2.3 REAR PANEL.................................................................................................................................................... 5
2.4 PREPARING FOR MMA WELDING.................................................................................................................. 6
2.5 PREPARING FOR TIG WELDING .................................................................................................................... 8
3COMMISSIONING........................................................................................................................................... 10
3.1 USER INTERFACE ......................................................................................................................................... 10
3.2 UNIT POWER-UP............................................................................................................................................ 13
3.3 RESET (LOAD FACTORY SETTINGS) .......................................................................................................... 13
3.3.1 PARTIAL RESET ................................................................................................................................................................. 13
3.3.2 TOTAL RESET .................................................................................................................................................................... 13
3.4 SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE)............................................................... 14
3.5 ALARMS MANAGEMENT ............................................................................................................................... 16
4WELDING SETTINGS..................................................................................................................................... 17
4.1 TORCH TRIGGER PROCEDURE................................................................................................................... 17
4.2 SELECTION OF THE WELDING MODE AND TORCH TRIGGER PROCEDURE......................................... 20
4.3 WELDING PARAMETERS .............................................................................................................................. 21
4.4 PARAMETERS ACTIVATION ......................................................................................................................... 23
4.5 PARAMETERS SETTING: (1ST LEVEL) ........................................................................................................ 24
4.6 PARAMETERS SETTING: (2ND LEVEL)........................................................................................................ 26
4.7 PARAMETERS SETTING: SPECIAL FUNCTIONS ........................................................................................ 26
4.8 JOBS MANAGEMENT..................................................................................................................................... 27
4.8.1 SAVING A JOB.................................................................................................................................................................... 27
4.8.2 LOADING A USER JOB OF FACTORY SET JOB.............................................................................................................. 27
4.8.3 DELETING A JOB................................................................................................................................................................ 27
5TECHNICAL DATA......................................................................................................................................... 28
6SPARE PARTS ............................................................................................................................................... 30
7ELECTRICAL DIAGRAM................................................................................................................................ 32
7.1 GL 502............................................................................................................................................................. 32
7.2 CONNECTOR FOR "COM1"........................................................................................................................... 32
7.3 CONNECTOR FOR "COM2"........................................................................................................................... 37
7.4 TORCH CONNECTOR.................................................................................................................................... 39
7.5 REMOTE CONTROLLER CONNECTOR........................................................................................................ 39

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1INTRODUCTION
IMPORTANT!
This handbook must be consigned to the user prior to
installation and commissioning of the unit.
Read the "General prescriptions for use" handbook supplied
separately from this handbook before installing and
commissioning the unit.
The meaning of the symbols in this manual and the associated
precautionary information are given in the "General
prescriptions for use”.
If the "General prescriptions for use" are not present, it is
mandatory to request a replacement copy from the manufacturer
or from your dealer.
Retain these documents for future consultation.
KEY
DANGER!
This pictogram warns of danger of death or serious injury.
WARNING!
This pictogram warns of a risk of injury or damage to property.
CAUTION!
This pictogram warns of a potentially hazardous situation.
INFORMATION
This pictogram gives important information concerning the execution
of the relevant operations.
This symbol identifies an action that occurs automatically as a
result of a previous action.
This symbol identifies additional information or a reference to a
different section of the manual containing the associated
information.
§
This symbol identifies a reference to a chapter of the manual.
*1
The symbol refers to the associated numbered note.
NOTES
The figures in this manual are purely guideline and the images may
contain differences with respect to the actual equipment to which they
refer.
INTRODUCTION
This professional and rugged welding power source for DC MMA and
TIG welding with exceptional arc characteristics is designed to
operate in harsh environmental conditions in the fields of professional
maintenance, shipyards and offshore, building construction and heavy
fabrication.
The combination of digital control and excellent welding with cellulosic
electrodes is ideal for hydraulic applications and welding work on oil
pipelines and in the petrochemical industry.
The ARC AIR function allows perfect deseaming with carbon
electrodes of up to 10 mm in diameter.
Up to 6 mm diameter electrode welding is possible in MMA.
In MMA welding the Hot Start and Arc Force functions are adjustable
and they allow improved arc striking, a flatter bead and more uniform
weld.
The Anti Sticking function makes it possible to detach the electrode
rapidly from the workpiece in the event of accidental sticking.
The parameters preset in the DC TIG pulsed synergic curve simplify
welding by regulation exclusively of the current.
The current is adjustable also from the Up-Down torch.
The simply and intuitive interface allows high precision adjustments
with 50 storable programs.
The wide range of adjustable pulsed frequency in combination with
the complementary parameters (base current and duty cycle) makes it
possible to weld in slow and fast pulsed mode.
Thanks to its modular configuration, the power source can be
configured out for MIG/MAG welding by adding a wire feed unit,
extension, and, if required, a cooling unit and power source transport
trolley.
Fan. The fan is turned on only during welding, at the end of the
welding process it remains on for a fixed period of time according to
welding conditions.
The fan is nonetheless controlled by specific thermal sensors that
guarantee a correct cooling of the machine.
Accessories/ancillary devices that can be connected to the unit:
-UP/DOWN torch or torch with potentiometer to adjust the welding
current from a distance.
-Manual remote controller for remote adjustment of the welding
current.
-Foot-pedal remote controller for TIG torch arc striking and remote
adjustment of welding current.
The maximum and minimum TIG welding current values can be
set with the foot pedal controller.
If both remote controllers are connected, the foot pedal assumes
priority over the UP/DOWN or potentiometer TIG torch.
-Liquid cooler for TIG torches.
-Power source trolley.
Consult your dealer for an updated list of accessories and the latest
available new products.

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2INSTALLATION
DANGER!
Lifting and positioning
Read the warnings highlighted by the following symbols in the
“General prescriptions for use”.
2.1 CONNECTIONS TO THE ELECTRICAL MAINS
NETWORK
The characteristics of the mains power supply to which the equipment
shall be connected are given in the section entitled “Technical data”
on page 28.
The machine can be connected to motorgenerators provided their
voltage is stabilised.
Connect/disconnect the various devices with the machine switched
off.
2.2 FRONT PANEL
1.
Connector for gas feed hose:
power source torch
2.
Connector for logic signals of TIG torch.
3.
Remote controller connector.
4.
TIG TORCH welding socket.
5.
Negative pole welding socket.
6.
Positive pole welding socket.
7.
Welding power source ON/OFF switch.
8.
Mains protection ON LED.
This LED illuminates if an incorrect operating condition occurs:
-absence of a phase in the power supply line.
2.3 REAR PANEL
1.
Power supply transformer fuse.
Type: Delayed acting (T)
Amperage: 2 A
Voltage: 500 V a.c.
2.
Signals connector for automatic application.
3.
Pre-heating unit power supply socket.
The socket is internally protected by a self-resetting fuse.
Power socket type: Schuko
Maximum power: 130 W
Voltage: 230 V a.c.
4.
Connector for gas feed hose:
cylinder power source
5.
Cooler power feeding connector.
Voltage: 400 V a.c.
Current output: 1.0 A
IP protection rating: IP20 (cap open) / IP66 (cap closed)
DANGER!
High voltage!
If the socket is not connected to any devices always close the cap:
presence of hazardous voltage levels!
7
1
2
4
3
5
6
8
9
1
2
3
4
5
7
8
6

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6.
Connector for connection to the programmer.
(Programming connector for the "frontal logic" circuit board)
You can update the software of the equipment using the
programming kit.
7.
Connector of the bundle of cables for connecting the power source
to the remote control device.
8.
Power cable.
Total length (including internal part): 5,0 m
Number and cross section of wires: 4 x 2,5 mm2
Power plug type: not supplied
9.
Socket for connecting the power cable between the power source
and the remote control device.
2.4 PREPARING FOR MMA WELDING
1.
Set the welding power source ON/OFF switch to “O” (unit de-
energized).
2.
Plug the power cable plug into a mains socket outlet.
3.
Choose the electrode based on the type of material and thickness
of the workpiece to be welded.
4.
Insert the electrode in the electrode holder.
5.
Connect the electrode holder cable to the welding socket based on
the polarity requested by the type of electrode used.
6.
Connect the plug of the ground clamp to the welding socket on the
basis of the polarity required.
7.
Connect the earth clamp to the workpiece being processed.
DANGER!
Electric shock hazard!
Read the warnings highlighted by the following symbols in the
“General prescriptions for use”.
8.
Set the welding power source ON/OFF switch to “I” (unit
powered).
9.
Select the following welding mode on the user interface: MMA
10.
Set the required welding parameter values on the user interface.
When the remote controller [RC] is connected and the relative
locking screw is tightened, welding current can be adjusted using
the remote controller.
The system is ready to start welding.

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(polarity to basic electrode)

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2.5 PREPARING FOR TIG WELDING
NOTE: For the cooler to power source assembly procedure refer
to the cooler instruction manual.
1.
Set the welding power source ON/OFF switch to “O” (unit de-
energized).
2.
Plug the power cable plug into a mains socket outlet.
3.
Connect the gas hose from the welding gas cylinder to the rear
gas socket.
4.
Open the cylinder gas valve.
5.
Choose the electrode based on the type of material and thickness
of the workpiece to be welded.
6.
Insert the electrode in the TIG torch.
7.
Connect the torch plug to the welding socket on the basis of the
polarity required by the type of electrode in question.
8.
Connect the plug of the ground clamp to the welding socket on the
basis of the polarity required.
9.
Connect the gas hose from the welding torch to the front gas
socket.
10.
Couple the welding torch connector to the TIG torch signals
connector.
11.
Connect the earth clamp to the workpiece being processed.
12.
Set the welding power source ON/OFF switch to “I” (unit
powered).
13.
Select the following welding mode on the user interface: DC TIG
14.
Press the torch trigger with the torch well clear of any metal parts.
This serves to open the gas solenoid valve without striking the
welding arc.
15.
Use the flow control valve to adjust the flow of gas as required
while the gas is flowing out.
16.
Set the required welding parameter values on the user interface.
When the remote control pedal is connected and the relative
locking screw is tightened the welding current will vary in relation
to the pressure exerted on the pedal.
The system is ready to start welding.

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(polarity for tungsten electrode)

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3COMMISSIONING
3.1 USER INTERFACE
CODE
SYMBOL
DESCRIPTION
L1
This LED illuminates to confirm the presence of power on the output sockets.
L2
This LED illuminates to show an anomaly in the operating conditions.
See § 3.5 ALARMS MANAGEMENT page 16.
L3
Illuminates to show that a previously saved JOB has been loaded.
L4
Illumination shows that the following function has been activated: HIGH FREQUENCY ARC STRIKE (HF)
L5
Illumination shows that the following function has been activated: VRD (reduced output voltage).
The no-load voltage between the welding sockets is switched from U0to Ur(see technical data).
L6
Illuminates to show a value in the following unit of measurement: AMPERES
L7
Illuminates to show the last voltage and current values measured during welding.
The value appears on the following displays: D1-D2
The LED switches off when a new welding procedure is started, or when any of the welding settings is modified.
L8
Illuminates to show a value in the following unit of measurement: VOLTS
L9
Illuminates to show a value in the following unit of measurement: MILLIMETRES
L10
Illuminates to show a value in the following unit of measurement: AMPERES
L11
Illuminates to show a value in the following unit of measurement: SECONDS
L12
Illuminates to show a value in the following unit of measurement: HERTZ
L13
Illuminates to show a value in the following unit of measurement: KILOHERTZ
L14
Illuminates to show a value in the following unit of measurement: PERCENTAGE
L15
When this LED illuminates the following parameter can be set: Q-START
L16
When this LED illuminates the following parameter can be set: DYNAMIC ARC
L17
When this LED illuminates the following parameter can be set: MULTI TACK
L18
When this LED illuminates the following parameter can be set: STARTING CURRENT
L19
When this LED illuminates the following parameter can be set: SLOPE UP
L20
When this LED illuminates the following parameter can be set: WELDING CURRENT

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CODE
SYMBOL
DESCRIPTION
L21
When this LED illuminates the following parameter can be set: SECOND CURRENT B-LEVEL
L22
When this LED illuminates the following parameter can be set: BASE CURRENT
L23
When this LED illuminates the following parameter can be set: PEAK TIME
L23+L24
When this LED illuminates the following parameter can be set: PULSED CURRENT FREQUENCY
L24
When this LED illuminates the following parameter can be set: BASE TIME
L25
When this LED illuminates the following parameter can be set: DOWN SLOPE
L26
When this LED illuminates the following parameter can be set: FINAL CURRENT
L27
When this LED illuminates the following parameter can be set: POST-GAS
L28
Illuminates to signal activation of a connected remote control unit, if available.
L29
This LED indicates that the current reference setting is imposed by the remote controller.
L30
Illumination shows that the following function has been activated: 2 stroke procedure.
L31
Illumination shows that the following function has been activated: 4 stroke procedure.
L32
Illumination shows that the following function has been activated: 4 stroke B-level procedure + high frequency arc strike
(HF).
L33
Illumination shows that the following function has been activated: 2 stroke spot procedure (Q-SPOT).
L34
This LED illuminates to show that the following welding mode is selected: MMA
L35
This LED illuminates to show that the following welding mode is selected: DESEAMING MODE
L36
This LED illuminates to show that the following welding mode is selected: TIG DC CONTINUOUS
L37
This LED illuminates to show that the following welding mode is selected: PULSED DC TIG
L38
This LED illuminates to show that the following welding mode is selected: SYNERGIC PULSED DC TIG
When this is on, it means that the synergic mode is active and that the operator can set just the welding current while the
other parameters are automatically regulated by the machine. The synergy is optimised by angle welding.
D1
Data setting: The display shows the acronym of the parameter to be set.
Welding: The display shows the effective amperes value during welding.
HOLD function: The display shows the average current value measured over the entire welding period (excluding the
starting and ending ramps).
D2
Data setting: The display shows the value of the selected parameter.
Welding: The display shows the effective voltage during welding operations.
HOLD function: The display shows the average voltage value measured over the entire welding period (excluding the
starting and ending ramps).
S1
Press the button to select the parameter to be set.
Possible choices: Q-START - DYNAMIC ARC - MULTI TACK
S2
Press and release: the button selects the first level menu parameters.
Hold down for 3 seconds: the button opens the second level menu. When in the menu press and release the button to
select the parameters.
Keep the button pressed while powering on the power source: the button opens the SETUP menu.
S3
Press and release: the button opens the JOBs upload menu.
Hold down for 3 seconds: the button opens the JOBs save and delete menu.
S4
Press and release: the button enables the device to receive the welding current control signal from a remote controller.
Hold down for 3 seconds: the button activates a connected remote controller, if available, which is then used to
manage all functions of the welding power source from a distance.

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CODE
SYMBOL
DESCRIPTION
S5
This button selects the torch trigger procedure.
See § 4.1 page 17.
S6
This button selects the welding mode.
E1
Data setting: The encoder sets the value of the selected parameter.
Welding: The encoder sets the value of the following parameter: WELDING CURRENT

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3.2 UNIT POWER-UP
Set the welding power source ON/OFF switch to “I” to switch on the unit.
FX.X
The message appears on the following displays: D2
x.x= software version
First power-up or power-ups following a RESET procedure
The welding power source sets up for welding with the factory presets.
Subsequent power-ups
The welding power source sets up for welding in the latest stable welding configuration that was active at the time of power-off.
3.3 RESET (LOAD FACTORY SETTINGS)
The reset procedure involves complete restoration of the default values, parameters and memory settings set in the factory.
The reset procedure is useful in the following cases:
-Too many changes made to the welding parameters so user finds it difficult to restore defaults.
-Unidentified software problems that prevent the welding power source from functioning correctly.
3.3.1 PARTIAL RESET
The reset procedure involves restoration of the parameter values and settings, except the following settings:
-Settings of the SETUP menu.
-saved JOBS.
Set the welding power source ON/OFF switch to “O” to switch the unit off.
S1
S6
Hold down both buttons simultaneously.
Set the welding power source ON/OFF switch to “I” to switch on the unit.
SIMULTANEOUS ACTIONS
rEC PAr
The message appears on the following displays: D1-D2
Exit without confirmation
Press any button (except S3).
This action will automatically close the menu.
Exit with confirmation
S3
Press the button.
Wait for the memory clear procedure to terminate.
This action will automatically close the menu.
3.3.2 TOTAL RESET
The reset procedure involves complete restoration of the default values, parameters and memory settings set in the factory.
All memory locations will be reset and hence all your personal welding settings will be lost!
Set the welding power source ON/OFF switch to “O” to switch the unit off.
S1
S6
Hold down both buttons simultaneously.
Set the welding power source ON/OFF switch to “I” to switch on the unit.
SIMULTANEOUS ACTIONS
rEC PAr
The message appears on the following displays: D1-D2
E1
Select the following setting with the encoder:
rEC FAC
Exit without confirmation
Press any button (except S3).
This action will automatically close the menu.
Exit with confirmation
S3
Press the button.
Wait for the memory clear procedure to terminate.
This action will automatically close the menu.

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3.4 SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE)
Set the welding power source ON/OFF switch to “O” to switch the unit off.
S2
Press the button.
Set the welding power source ON/OFF switch to “I” to switch on the unit.
SIMULTANEOUS ACTIONS
SEt UP
The message appears for a few seconds on the following displays: D1-D2
Coo Aut
The message appears on the following displays: D1-D2
S2
Use this button to scroll the settings to edit.
E1
Using the encoder, edit the value of the selected setting.
Exit without confirmation
Press any button (except S2).
This action will automatically close the menu.
Exit with confirmation
S2
Press the button.
This action will automatically close the menu.
Tab. 1 - Setup settings
ACRONYM
SETTING
MIN
DEFAULT
MAX
Coo
COOLER ACTIVATION
Aut
Aut
oFF
St.C.
STARTING CURRENT
%
%
A
F.Cu.
FINAL CURRENT
%
%
A
HF.C.
HF CURRENT
20 A
SYn
250 A
PUL.
TYPE OF PULSED CURRENT
SLo.
FA.
FA.
P.A.
PILOT ARC
oFF
on
on
E.C.C.
CONTACT COMMAND EXPANSION
oFF
oFF
on
COOLER ACTIVATION
ON=
The cooler is always running when the power source is switched on. This mode is preferable for heavy duty and automatic welding
procedures.
OFF=
The cooler is always disabled because an air-cooled torch is in use.
AUT=
When the unit is switched on the cooler is switched on for 15 s. During welding procedures the cooler runs constantly. When welding is
terminated the cooler continues to run for 90 s + a number of seconds equivalent to the average current value shown using the HOLD
function.
Torch loading
WARNING!
Make sure the torch in use is correctly sized in relation to the welding current required and for the available and selected cooling type. This
prevents the risk of burns to which the operator is potentially exposed, potential faults, and irreversible damage to the torch and the system.
If a torch is installed or replaced while the unit is running, the circuit of the newly installed must be filled with coolant to avoid the risk of damage
to the torch in the case of high voltage arc strikes without any liquid in the circuit.
Power-up with operation of the cooler set to "ON" or "AUT" mode
A check is performed automatically of the presence of liquid in the cooling circuit and the cooler is switched on for 15 seconds.
If the coolant circuit is full, the power source sets up in the most recent stable welding configuration.
If the coolant circuit is not full, all functions are inhibited and there will be no output power present.
AL. Coo.
The message appears on the following displays: D1-D2
(any)
Press the button or torch trigger to repeat the checking procedure for an additional 15 seconds.
If the problem persists rectify the cause of the alarm.
Power-up with operation of the cooler set to "OFF"
Operation of the cooler and the cooler alarm are disabled.
Welding is performed without liquid cooling of the torch.
Torch change-over with operation of the cooler set to "ON"
Press and release the torch trigger.
This serves to start the cooler for 15 seconds to fill the torch cooling circuit.
STARTING CURRENT
The value of this parameter can be set as a percentage of the welding current or as an absolute value expressed in Amperes.

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FINAL CURRENT
The value of this parameter can be set as a percentage of the welding current or as an absolute value expressed in Amperes.
HF CURRENT
This parameter establishes the current value during HF discharge. The value of this parameter can be set as an absolute value or in SYN.
With SYN setting the HF current value is calculated automatically on the basis of the preset welding current value.
Consequences of a higher value:
-Arc striking is facilitated, even on very dirty workpieces.
-Risk of piercing excessively thin gauge workpieces.
TYPE OF PULSED CURRENT
SLo.=
This setting enables slow pulsed mode.
FA.=
This setting enables fast pulsed mode.
PILOT ARC
The function enables the output of a low current between the 1st and 2nd times of the torch trigger to shield the mask in advance and avoid the
risk of blinding flashback caused by the welding current.
CONTACT COMMAND EXPANSION
The function enables the emission of the ARC-ON and ALARM signals via the signals connector for automatic application (See § 7.3 page 37).

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3.5 ALARMS MANAGEMENT
This LED illuminates if an incorrect operating condition occurs.
An alarm message appears on the following display: D2
Tab. 2 - Alarm messages
MESSAGE
MEANING
EVENT
CHECKS
AL. HEA.
Overheating alarm
Indicates tripping of the welding power source thermal
protection.
Leave the unit running so that the overheated
components cool as rapidly as possible.
When the unit has cooled, the welding power source
will reset automatically.
All functions disabled.
Exceptions:
-Cooling fan.
-Cooler (if switched on).
-Make sure that the power required by the
welding process is lower than the maximum
rated power output.
-Check that the operating conditions are in
compliance with the welding power source
data plate specifications.
-Check for the presence of adequate air
circulation around the welding power source.
Phase missing alarm
Indicates the absence of a phase in the power supply
line.
The message appears when the mains protection
activation LED switches on.
All functions disabled.
Exceptions:
-Cooling fan.
-Check if the equipment power supply line has
all the phases.
If the problem persists:
-qualified technical personnel are required
for repair/maintenance jobs.
AL. Coo.
Cooler alarm
Indicates insufficient pressure in the torch liquid
cooling circuit.
All functions disabled.
Exceptions:
-Cooling fan.
The alarm message persists on the
display until the first operation is
performed on the user interface.
Signalling of the alarm depends on
the following settings:
-Coo = on: the alarm is signalled
if the cooling unit is connected to
the power source and if it is
running.
-Coo = oFF: the alarm is never
signalled, irrespective of the
circumstances.
-Coo = Aut: the alarm is signalled
if the cooling unit is connected to
the power source and if it is
running.
-Check that the connection to the cooler is
correct.
-Check that the "O/I" switch is set to "I" and
that it illuminates when the pump is running.
-Check that the cooler is filled with coolant.
-Check that the cooling circuit is liquid tight,
notably the torch hoses and the internal
connections of the cooler.
E. 69
Software compatibility error
Indicates that the welding power source has a
software version that is not compatible with the
remote device connected to it (remote controller, wire
feed unit).
All functions disabled.
Exceptions:
-Cooling fan.
-Update the remote device software.
E. 04
Alarm, no-load voltage failure
All functions disabled.
Exceptions:
-Cooling fan.
-Check to ensure the welding torch is not
resting on the workpiece connected to ground.
-Check that when the power source is switched
on there is no short circuit between the
sockets (voltage must be greater
than/equivalent to Ur).
If the problem persists:
-qualified technical personnel are required for
repair/maintenance jobs.
CAn Err.
No communication alarm
Indicates the presence of problems in data
communication between the power source and wire
feeder. When the unit has cooled, the welding power
source will reset automatically.
Exit the alarm state by performing one of the following
actions:
Switch the power source off.
All functions disabled.
Exceptions:
-cooling fan.
-cooler (if switched on).
-Check that the connecting cable between
power source and wire feeder is intact and
make sure the connectors are securely
tightened.
If the problem persists:
-qualified technical personnel are required for
repair/maintenance jobs.

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4WELDING SETTINGS
4.1 TORCH TRIGGER PROCEDURE
2 STROKE LIFT-ARC WELDING (2T)
1.
Touch the workpiece with the torch electrode.
2.
Press (1T) and keep the torch trigger pressed.
3.
Slowly lift the torch to strike the arc.
The welding current reaches the preset value, by way of a up slope time, if programmed.
4.
Release (2T) the trigger to start the weld completion procedure.
The current reaches the end current value in the time set in the down slope time parameter.
The arc is extinguished.
Gas delivery continues for the time set in the post gas parameter.
2 STROKE WELDING WITH HIGH FREQUENCY ARC STRIKE (2T HF)
1.
Bring the torch up to the work until the electrode tip is approximately 2 or 3 mm away.
2.
Press (1T) and keep the torch trigger pressed.
The arc strikes without contact with the workpiece and the voltage discharges (HF) cease automatically.
The welding current reaches the preset value, by way of a up slope time, if programmed.
3.
Release (2T) the trigger to start the weld completion procedure.
The current reaches the end current value in the time set in the down slope time parameter.
The arc is extinguished.
Gas delivery continues for the time set in the post gas parameter.
4 STROKE LIFT-ARC WELDING (4T)
1.
Touch the workpiece with the torch electrode.
2.
Press (1T) and release (2T) the torch trigger.
3.
Slowly lift the torch to strike the arc.
The welding current reaches the preset value, by way of a up slope time, if programmed.
4.
Press (3T) the trigger and keep it pressed to start the weld completion procedure.
The current reaches the end current value in the time set in the down slope time parameter.
The arc continues and the current output will be the value set in the end current parameter.
In these conditions the weld pool can be closed (crater filler current).
5.
Release (4T) the trigger to extinguish the arc.
Gas delivery continues for the time set in the post gas parameter.
4 STROKE WELDING WITH HIGH FREQUENCY ARC STRIKE (4T HF)
1.
Bring the torch up to the work until the electrode tip is approximately 2 or 3 mm away.
2.
Press (1T) and release (2T) the torch trigger.
The arc strikes without contact with the workpiece and the voltage discharges (HF) cease automatically.
The welding current reaches the preset value, by way of a up slope time, if programmed.
3.
Press (3T) the trigger and keep it pressed to start the weld completion procedure.
The current reaches the end current value in the time set in the down slope time parameter.
The arc continues and the current output will be the value set in the end current parameter.
In these conditions the weld pool can be closed (crater filler current).
4.
Release (4T) the trigger to extinguish the arc.
Gas delivery continues for the time set in the post gas parameter.
4 STROKE B-LEVEL WELDING (4T B-L)
1.
Touch the workpiece with the torch electrode.
2.
Press (1T) and release (2T) the torch trigger.
3.
Slowly lift the torch to strike the arc.
The welding current reaches the preset value, by way of a up slope time, if programmed.
3.
Press and immediately release the torch trigger to switch to the second welding current.
The trigger must not be pressed for more than 0.3 seconds; otherwise, the weld completion stage will start.
When the trigger is pressed and released immediately, the system returns to the welding current.
4.
Press (3T) the trigger and keep it pressed to start the weld completion procedure.
The current reaches the end current value in the time set in the down slope time parameter.
The arc continues and the current output will be the value set in the end current parameter.
In these conditions the weld pool can be closed (crater filler current).
5.
Release (4T) the trigger to extinguish the arc.
Gas delivery continues for the time set in the post gas parameter.

Cod.006.0001.1681
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ENGLISH
GL 502
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4 STROKE B-LEVEL WELDING WITH HIGH FREQUENCY ARC STRIKE (4T B-L HF)
1.
Bring the torch up to the work until the electrode tip is approximately 2 or 3 mm away.
2.
Press (1T) and release (2T) the torch trigger.
The arc strikes without contact with the workpiece and the voltage discharges (HF) cease automatically.
The welding current reaches the preset value, by way of a up slope time, if programmed.
3.
Press and immediately release the torch trigger to switch to the second welding current.
The trigger must not be pressed for more than 0.3 seconds; otherwise, the weld completion stage will start.
When the trigger is pressed and released immediately, the system returns to the welding current.
4.
Press (3T) the trigger and keep it pressed to start the weld completion procedure.
The current reaches the end current value in the time set in the down slope time parameter.
The arc continues and the current output will be the value set in the end current parameter.
In these conditions the weld pool can be closed (crater filler current).
5.
Release (4T) the trigger to extinguish the arc.
Gas delivery continues for the time set in the post gas parameter.
2 STROKE TACKING WELDING (2T Q-SPOT)
1.
Touch the workpiece with the torch electrode.
2.
Press (1T) and keep the torch trigger pressed.
3.
Slowly lift the torch to strike the arc.
4.
Release (2T) the torch trigger.
The welding current reaches the preset value, by way of a up slope time, if programmed.
The welding procedure continues, at the preset current, for the time set with the spot time parameter.
The current reaches the end current value in the time set in the down slope time parameter.
The arc is extinguished.
Gas delivery continues for the time set in the post gas parameter.
2 STROKE TACKING WELDING WITH HIGH FREQUENCY ARC STRIKE (2T Q-SPOT HF)
1.
Bring the torch up to the work until the electrode tip is approximately 2 or 3 mm away.
2.
Press (1T) the torch trigger.
The arc strikes without contact with the workpiece and the voltage discharges (HF) cease automatically.
3.
Release (2T) the torch trigger.
The welding current reaches the preset value, by way of a up slope time, if programmed.
The welding procedure continues, at the preset current, for the time set with the spot time parameter.
The current reaches the end current value in the time set in the down slope time parameter.
The arc is extinguished.
Gas delivery continues for the time set in the post gas parameter.
Keep pressed torch trigger procedure
1.
Bring the torch up to the work until the electrode tip is approximately 2 or 3 mm away.
2.
Press (1T) the torch trigger.
The arc strikes without contact with the workpiece and the voltage discharges (HF) cease automatically.
The welding current reaches the preset value, by way of a up slope time, if programmed.
The welding procedure continues, at the preset current, for the time set with the spot time parameter.
The current reaches the end current value in the time set in the down slope time parameter.
The arc is extinguished.
Gas delivery continues for the time set in the post gas parameter.
3.
Touch the workpiece with the torch electrode.
4.
Slowly lift the torch to strike the arc.

GL 502
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23/04/2014 v2.0
ENGLISH
19/40
PILOT ARC WELDING
The pilot arc can be activated in the following torch trigger procedures:
-4T WELDING
-4T HF WELDING
-4T B-L HF WELDING
The welding procedure with pilot arc differs with respect to the procedure without pilot arc in the part of the torch trigger procedure described
below.
LIFT-ARC Welding
1.
Touch the workpiece with the torch electrode.
2.
Press (1T) and keep the torch trigger pressed.
3.
Slowly lift the torch to strike the arc.
The arc strikes, the welding current assumes the pilot current value.
4.
Release (2T) the torch trigger.
The welding current reaches the preset value, by way of a up slope time, if programmed.
etc.
Welding with HF
1.
Press (1T) and keep the torch trigger pressed.
The arc strikes without contact with the part and the voltage discharges (HF) cease automatically, the welding current will assume the pilot
current value.
2.
Release (2T) the torch trigger.
The welding current reaches the preset value, by way of a up slope time, if programmed.
etc.