Linde RYVAL 160 T PULSE HF User manual

Linde AG, Linde Gas Deutschland © Ryval 160-200 T PULSE F manual EN 03
WELDING INVERTER
RYVAL 160 T PULSE HF
RYVAL 200 T PULSE HF
OPERATING MANUAL

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CONTENT:
INTRODUCTION .......................................................................................... 3
SAFETY INSTRUCTIONS AND WARNINGS ....................................... 4
TEC NICAL DATA ...................................................................................... 6
EQUIPMENT ................................................................................................ 7
OPERATOR CONTROLS ............................................................................ 8
GETTING STARTED ................................................................................. 12
TWO STROKE AND FOUR STROKE IN TIG MODE ............................... 13
ROUTINE MAINTENANCE & INSPECTION ............................................. 14
STATEMENT OF WARRANTY .................................................................. 15
DISPOSAL ................................................................................................ 16

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INTRODUCTION
Congratulations on your new Linde AG, Linde Gas Deutschland product. We are
proud to have you as our customer and will strive to provide you with the best
service and reliability in the industry.
This Operating Manual has been designed to instruct you on the correct use and
operation of your Linde AG, Linde Gas Deutschland product. Your satisfaction
with this product and its safe operation is our ultimate concern. Therefore please
take the time to read the entire manual, especially the Safety Precautions. They
will help you to avoid potential hazards that may exist when working with this
product.
Read and understand this entire Manual and your employer’s safety practices
before installing, operating, or servicing the equipment. While the information
contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Ryval 160-200 T PULSE F weld by those methods
a) E – (MMA) coated electrodes up to 4,0 mm
b) TIG F ( igh Frequency ignition)
c) TIG lift arc.
Welding machines Ryval 160-200 T PULSE F have these function: pre-gas,
post-gas, up slope, down slope, final current, high frequency ignition, two stroke
and four stroke, pulsed mode, bilevel, UP-DOWN control from the torch.
In MMA method are machines equipped with functions OT START, ARC
FORCE and ANTISTICK.
In TIG method are machines equipped with function „fan as required“ (if it is not
necessary to cool the machine, it automatically shuts down the fan).

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SAFETY INSTRUCTIONS AND WARNINGS
1. Once the packing has been opened, make sure that the machine is not
damaged. If in any doubt, call the service centre.
2. This equipment must only be used by qualified personnel.
3. During installation, any electric work must only be carried out by trained
personnel.
4. The machine must be used in a dry place with good ventilation.
5. Make sure that no metal dust can be drawn in by the fan inside the machine,
as this could cause damage to the electronic circuits.
6. It is prohibited to connect more than one INVERTER generator in series or in
parallel.
7. When installing the machine, follow the local regulations on safety.
8. The position of the machine must allow easy access by the operator to the
controls and connectors.
9. When the welding machine is operating, all its covers and doors must be
closed and well fixed.
10. Do not expose the welding machine to direct sunlight or to heavy rain. This
equipment conforms to protection rating IP23S.
11. During welding, the welding cables must be located near or at ground level.
They should be as short as possible.
12. The operator must wear gloves, clothes, shoes, and a helmet or a welder’s
helmet, which protect and are fire-resistant in order to protect him against
electric shock, flashes and sparks from welding.
13. The operator must protect his eyes with safety visor or mask designed for
welding, fitted with standard safety filters. e should also be aware that during
electrical welding ULTRAVIOLET RADIATION is emitted. Therefore it is vital
that his face is also protected from radiation. Ultraviolet rays produce the
same harmful effect as sun burning on unprotected skin.
14. The operator is obliged to warn anyone near the welding area of the risks
that welding involves and to arrange to provide adequate protection
equipment.
15. It is very important to arrange for sufficient ventilation, especially when
welding in enclosed spaces. We suggest using suitable fume extractors to
prevent the risk of intoxication by fumes or gas generated by the welding
process.
16. The operator must ensure all flammable materials are removed from the
work area to avoid any risk of fire.
17. The operator must NEVER weld containers that have previously contained
petrol, lubricants, gas or similar flammable materials, even if the container
has been empty for a considerable time. T ERE IS A VERY IG RISK OF
EXPLOSION.
18. The operator must be aware of all the special regulations which he needs
to conform to when welding in enclosed spaces with a high risk of explosion.
19. To prevent electric shock, we strongly suggest the following rules:

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20. Do not work in a damp or humid environment.
21. Do not use the welding machine if its cables are damaged in any way.
22. Make sure that the earthing system of the electric equipment is correctly
connected and operational.
23. The operator must be insulated from the metal components connected to
the return wire.
24. The earthing of the piece being worked could increase the risk of injury to
the operator.
25. EN 60974-1 Standard: Open-circuit voltage. During the operation of the
machine, the highest voltage, with which it is possible to come into contact, is
the open-circuit voltage between the welding clamps. In our generator this
voltage is 61V respective 65 V.
26. The maximum open-circuit voltage of the welding machines is established
by national and international standards (EN 60974-1) depending on the type
of weld current to be used, on its waveform and on the hazards arising from
the work place. These values are not applicable to the strike currents and
those for stabilisation of the arc that could be above it.
27. The open-circuit voltage, for as many adjustments as possible, must never
exceed the values relating to the various cases shown in the following table:
Case
Working conditions
Open
-
circuit voltage
1 Places with increased risk of
electric shock
DC current: 113V
peak value
AC current: 68V
peak value and
48V effective
2 Places without increased risk
of electric shock
DC current: 113V
peak value
AC current: 113V
peak value and
80V effective
3 Torches held mechanically
with increased protection for
the operator
DC current: 141V
peak value
AC current: 141V
peak value and
100V effective
28. In case 1, the dc welding machines with rectifier must be built in such a
way that, in case of a fault developing in the rectifier (for example open circuit,
short circuit or lack of power), the permitted values cannot be exceeded. The
welding machines of this type can be marked with the symbol:
S
29. Before opening the machine switch off the machine and disconnect it from
the power socket.
30. Only personnel authorised by this company can carry out maintenance on
the machine.
NOTE:
Device complies with IEC 61000-3-12.

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ELECTROMAGNETIC COMPATIBILITY
The welding device is in terms of interference designed primarily for industrial
areas. It meets the requirements of EN 60974-10 class A and it isn’t designed
for using in residential areas, where the electrical energy is supplied by public
low-voltage power supply network. It can be here potential problems with
ensuring of electromagnetic compatibility in this areas, due to interference
caused by power lines as well as the radiated interference.
During operation, the device may be the source of interference.
 Caution  We warn users , that they are responsible for possible
interference from welding.
TECHNICAL DATA
RYVAL 160 T PULSE HF
Method MMA TIG
Mains voltage V/ z 1x230/50-60
Welding current range A 5 - 160 5 - 160
Open-circuit voltage U
20
V 63,0 63,0
Mains protection A 16 @
Max. effective current I
1eff
A 16,0 10,8
Welding current (DC=100%) I
2
A 80 80
Welding current (DC=60%) I
2
A 100 100
Welding current (DC=x%) I
2
A 25% = 160 25% = 160
Protection IP23S
Standards EN 60974-1, EN 60974-10 cl. A
Dimensions (w x l x h) mm 130 x 375 x 230
Weight kg 7,3
RYVAL 200 T PULSE HF
Method MMA TIG
Mains voltage V/ z 1x230/50-60
Welding current range A 5 - 170 5 - 200
Open-circuit voltage U
20
V 63,0 63,0
Mains protection A 16 @ (20 @)
Max. effective current I
1eff
A 16,0 (18,8) 14,5 (14,5)
Welding current (DC=100%) I
2
A 80 (100) 100 (100)

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Welding current (DC=60%) I
2
A 110 (120) 120 (120)
Welding current (DC=x%) I
2
A 20%=170
(30%=170)
25%=200
(25%=200)
Protection IP23S
Standards EN 60974-1, EN 60974-10 cl. A
Dimensions (w x l x h) mm 130 x 375 x 230
Weight kg 7,3
The machine is equipped with a 16 A plug for connection to a single phase
supply 1 x 230 V, the corresponding data for this 16 A plug (Duty Cycle = DC)
are in the table above without brackets.
In order to fully use the technical capabilities of the machine, the machine must
be connected to the industrial single phase networks with a blue plug 32 A with
the maximum permissible fuse of 25 A. The corresponding data for such a 32 A
plug are stated in the table above in brackets.
Replacement of the plug may only be performed by Linde AG, Linde Gas
Deutschland as authorized service personnel.
Linde AG, Linde Gas Deutschland continuously strives to produce the best
product possible and therefore reserves the right to change, improve or revise
the specifications or design of this or any product without prior notice. Such
updates or changes do not entitle the buyer of equipment previously sold or
shipped to the corresponding changes, updates, improvements or replacement
of such items.
EQUIPMENT
PART OF THE DELIVERY
Item N . Descripti n
RYVAL T PULSE F
5847 Set Connectors ST 12 PIN
8.462.124 Quick connector RYVAL female
ACCESSORIES ON REQUEST
Item N . Descripti n
VM0321-2 ose Gas 3m RYVAL quick connector G1/4
17FSL4ST Torch PARKER SGT 17 4m 35-50 FX ST
17FSL4STUD Torch PARKER SGT 17 4m 35-50 FX ST UD
17FSL8ST Torch PARKER SGT 17 8m 35-50 FX ST
VM0253 Welding Cable Set 2x 3m 35-50 200A
6008 Pressure Reducer FIXICONTROL Ar 2 manometers GCE
5.0178 Box for RYVAL BLACK 50x58,5x18 cm

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7.511.249 Belt Ryval
S7SUN9B Welding elmet S9B Shooting Blue Shark
S7SUN9BBlack Welding elmet S9B Shooting Blue Shark Black
3178 Gas Cylinder Argon 5 l
3176 ose AR 1m with manom.
6053 MAGNET ON/OFF 40 kg
6052 MAGNET ON/OFF 75 kg
OPERATOR CONTROLS
MAIN PARTS
Fig . 1 Main parts
P s. Descripti n
1 Operating panel LED ON
2 Gas outlet connector

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3 Panel quick connector -
4 Torch control connector
5 Panel quick connector +
6 ON/OFF switch
7 Mains socket with a plug
8 Gas inlet connector
OPERATING PANEL
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
P s. Descripti n
9 LED OT START – only MMA (1-10 s, default 5 s)
10 LED ARC FORCE - only MMA (1-10, default 3)
11 LED ON
12 LED over heating or over voltage in the mains
13 Display
14 LED PULSE selected – only TIG
15 MMA – position of the method switch 17, can be set current 25,
OT START
9
or ARC FORCE
10
by means of the encoder
21
16 Adjusting the gas flow - position of the method switch 17
17 Meth d switch
1.
MMA
c ated
electr de

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2. TIG Adjusting the gas flow - it is not possible to weld in this
position
3. TIG LA start 4T
4. TIG LA start 2T
5. TIG HF start 4T
6.
TIG HF start 2T
18 TIG LA 4T – Lift Arc ignition TIG, four stroke - position of the
method switch
17
19
TIG LA 2T – Lift Arc ignition TIG - position of the method switch 17,
the start current and end current are set to 5 A, impossible to
change.
20 TIG F 4T –TIG F ignition, four stroke - position of the method
switch
17
21
ENCODER
1. Every press f the enc der switches between selecting
m de f the parameter t be set and setting m de f the
selected parameter
2. By means f turning selects the parameters t be set
respective sets the selected parameters.
3. Sets the current 25 – that functi n is active strait after
switching the machine ON r if n pressing f the
enc der was d ne.
22 LED pre gas time - only TIG (0-1 s, default 0,1 s)
23 LED start current - only TIG (5-160 A, 5-200 A, default 50 A)
24 LED up slope time - only TIG (0-10 s, default 0 s)
25 LED welding current – all meth ds
26 LED lower current – only TIG, just in case the pulse LED 14
illuminates
(5
-
160 A, default 64 A; 5
-
200 A, default 64 A)
27 LED pulse frequency - only TIG, just in case the pulse LED 14
illuminates
(0,5
-
100 z, default 100 z)
28 LED pulse width - only TIG, just in case the pulse LED 14
illuminates
(5
-
100%, default 50%)
29 LED down slope time - only TIG (0-10 s, default 0 s)
30 LED end current - only TIG (5-160 A, 5-200 A, default 5 A)
31 LED post gas time - only TIG (0,1-10 s, default 10 s)
32 TIG F 2T –TIG F ignition, two stroke - position of the method
switch
17

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PRINCIPLE OF SETTING PARAMETERS
1. The machine will be the Main M de after switching ON - LED 25 will
illuminate and turning the encoder 21 will change main welding current
.
2. Turning the encoder 21 changes parameters.
3. Pressing the encoder 21 activates function of selecting a new parameter to
be set. That function will stay active just for 3 s. In case there is no movement
of the encoder during the period of those 3 s the function deactivates and the
machine switches automatically into the Main Mode.
4. After selection of a LED of a parameter to be set, appropriate LED will start
flashing. That function will stay active just for 3 s. It is possible to change the
value of the appropriate parameter by means of encoder 21 during that time.
5. To save the setting press the encoder 21 or wait for more than 3 s
6. The machine will switch back to the Main Mode after any change of setting 3
s later of last movement of the encoder 21.
EN EXAMPLE OF SETTING
1. Select method by means of method switch 17, LED 25 will illuminate
.
2. Press the encoder 21, then by means of turning the encoder select
LED 24 .
3. Press again the encoder 21, LED 24 will start flashing. Now you can change
the up slope time by means of turning the encoder 21.
4. Press the encoder 21 third time. That will save the change of the parameter.
In case you omit to press the encoder for the third time the machine will save
the parameter change automatically after 3 s of no movement of the encoder
21. LED 25 will illuminate then.
SELECTING PULSE MODE
1. Select the required TIG method by means of method switch 17, LED 25 will
illuminate .
2. Press the encoder 21, then by means of turning the encoder select
LED 14 .

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3. Press again the encoder 21, LED 14 will flash. Press the encoder 21 for the
third time. On the display will appear “ON”. The function will be automatically
saved and LED 25 – main welding current will become active.
4. One can set off the pulse similarly. Just select “OFF“.
GETTING STARTED
Getting started must be consistent with technical data and conditions of use.
Insert the mains plug into a suitable 1x230 V mains socket. The supply fuses or
circuit breaker should correspond to the technical data in section 3. Switch the
machine on by the ON/OFF switch 6.
GETTING STARTED MMA – COATED ELECTRODE
1. Set the method switch 17 to position 15 MMA.
2. Connect the welding cables to the panel quick connectors 3 and 5 (+ - )
according the instruction on the electrodes packing.
3. Set the welding current by means of encoder 21. The values will be showed
on the display 13.
4. You may adjust OT START and ARC FORCE similarly to EN EXAMPLE OF
SETTING.
5.
NOTE 
Prevent t uching the electr de any metal material f r in
this m de the terminals (5) and (6) are under current.
6. Insert the coated electrode into the electrode holder and you may start
welding.
GETTING STARTED TIG
1. Fit the TIG Torch to the Panel quick connector - 3 and fasten it by turning the
connector to the right.
2. Connect the work lead to Panel quick connector + 5 and fasten it by turning
the connector to the right.
3. Connect the to the reduction valve on the gas cylinder and on the Gas inlet
connector 8.
4. Connect the gas hose of the TIG torch onto Gas outlet connector 2.
5. Connect the torch control connector onto the matching connector 4.
6. Connect the work clamp to the work piece or at the welding table.
7. Set the method switch 17 to desired TIG method.

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Symb l Descripti n
4T LA – four stroke, contact ignition – Lift Arc
2T LA – two stroke, contact ignition – Lift Arc
4T F – four stroke, F ignition ( igh Frequency)
2T F – two stroke, F ignition ( igh Frequency)
TWO STROKE AND FOUR STROKE IN TIG MODE
TWO STROKE – 2T
Gas
Pregas Postgas
Down
slope
Welding current
Current

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FOUR STROKE – 4T
BILEVEL – SECOND WELDING CURRENT
When the machine is in 4T mode, there is always active the BILEVEL function.
The value of the second current is automatically set to 50% of the pre-set value
of the main welding current. To enter the second welding current press the torch
button for a short time and release it. To get back to the main welding current
press the torch button for a short time and release it.
ROUTINE MAINTENANCE & INSPECTION
1. The only routine maintenance required for the Ryval range of machines is a
thorough cleaning and inspection, with the frequency depending on the usage
and the operating environment.

WARNING

2. Disconnect the Ryval from the mains supply voltage before disassembling.
3. Special maintenance is not necessary for the control unit parts in the Welder.
If these parts are damaged for any reason, replacement is recommended.

CAUTION

4. Do not blow air into the welder during cleaning. Blowing air into the welder
can cause metal particles to interfere with sensitive electronic components
and cause damage to the welder.
5. To clean the welder, disconnect it from the mains supply voltage then open
the enclosure and use a vacuum cleaner to remove any accumulated dirt and
dust. The welder should also be wiped clean. If necessary, solvents that are
recommended for cleaning electrical apparatus may be used.
6. Troubleshooting and repairing of Ryval welding equipment should only be
carried out only by suitably qualified or competent person.
7. A ‘competent person’ must be a person who has acquired through training,
Gas
Down slope
Post
gas
1
Up slope
Pregas
Welding current
Current

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qualification or experience, or a combination of them, the knowledge and
skills enabling that person to safely carry out a risk assessment and repairs
to the electrical equipment in question.
8. The person carrying out the servicing needs and repairs must know what to
look at, what to look for and what to do.
STATEMENT OF WARRANTY
1. In accordance with the warranty periods stated below, Linde AG, Linde Gas
Deutschland guarantees the proposed product to be free from defects in
material or workmanship when operated in accordance with the written
instructions as defined in this operating manual.
2. Linde AG, Linde Gas Deutschland welding products are manufactured for use
by commercial and industrial users and trained personnel with experience in
the use and maintenance of electrical welding and cutting equipment.
3. Linde AG, Linde Gas Deutschland will repair or replace, at its discretion, any
warranted parts or components that fail due to defects in material or
workmanship within the warranty period. The warranty period begins on the
date of sale to the end user.
4. If warranty is being sought, please contact your Linde AG, Linde Gas
Deutschland product supplier for the warranty repair procedure.
5. Linde AG, Linde Gas Deutschland warranty will not apply to:
6. Equipment that has been modified by any other party other than Linde AG,
Linde Gas Deutschland’s own service personnel or with prior written consent
obtained from Linde AG, Linde Gas Deutschland Service Department.
7. Equipment that has been used beyond the specifications established in the
operating manual.
8. Installation not in accordance with the installation/operating manual.
9. Any product that has been subjected to abuse, misuse, negligence or
accident.
10. Failure to clean and maintain (including lack of lubrication, maintenance
and protection), the machine as set forth in the operating, installation or
service manual.
11. Within this operating manual are details regarding the maintenance
necessary to ensure trouble free operation.

NOTE

12. Warranty repairs must be performed by either an Linde AG, Linde Gas
Deutschland Service Centre, an Linde AG, Linde Gas Deutschland distributor
or an Authorised Service Agent approved by the company Linde AG, Linde
Gas Deutschland.

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DISPOSAL
Only for EU countries. Do not dispose of electric tools together with
household waste material.
In accordance with European Council Directive 2002/96/EC on
electrical and electronic equipment waste and its implementation in accordance
with national law, electric tools that have reached the end of their service life
must be collected separately and returned to an environmentally compatible
recycling facility.