Linde RYVAL 200 AC/DC dave User manual

Linde AG, Linde Gas Deutschland © RYVAL 200 AC-DC (PULSE) da e manual EN 05
WELDING INVERTER
RYVAL 200 AC/DC PULSE dave
RYVAL 200 AC/DC dave
OPERATING MANUAL

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CONTENT
1. INTRODUCTION .......................................................................................... 3
2. SAFETY INSTRUCTIONS AND WARNINGS ............................................. 4
3. TECHNICAL DATA ...................................................................................... 6
4. EQUIPMENT ................................................................................................ 7
5. OPERATOR CONTROLS ............................................................................ 8
6. GETTING STARTED ................................................................................. 11
7. TWO STROKE AND FOUR STROKE IN TIG MODE ............................... 15
8. GENERAL INFORMATION ON THE WELDING MODES......................... 16
9. ROUTINE MAINTENANCE & INSPECTION ............................................. 17
10. STATEMENT OF WARRANTY ................................................................ 17
11. DISPOSAL ................................................................................................ 18

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1. INTRODUCTION
Congratulations on your new Linde AG, Linde Gas Deutschland product. We are
proud to ha e you as our customer and will stri e to pro ide you with the best
ser ice 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 a oid 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 ser icing the equipment. While the information
contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
RYVAL 200 AC/DC PULSE dave welds by those methods:
1. E – (MMA) DC coated electrodes
2. E – (MMA) AC coated electrodes
3. TIG DC (Lift arc or High Frequency ignition)
4. TIG AC (Lift arc or High Frequency ignition)

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2. 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 ser ice 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 entilation.
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 co ers and doors must be
closed and well fixed.
10. Do not expose the welding machine to direct sunlight or to hea y
rain. This equipment conforms to protection rating IP23S.
11. During welding, the welding cables must be located near or at ground
le el. They should be as short as possible.
12. The operator must wear glo es, 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 isor or mask
designed for welding, fitted with standard safety filters. He should also be
aware that during electrical welding ULTRAVIOLET RADIATION is
emitted. Therefore it is ital that his face is also protected from radiation.
Ultra iolet 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 in ol es and to arrange to pro ide adequate protection
equipment.
15. It is ery important to arrange for sufficient entilation, especially
when welding in enclosed spaces. We suggest using suitable fume
extractors to pre ent the risk of intoxication by fumes or gas generated by
the welding process.
16. The operator must ensure all flammable materials are remo ed from
the work area to a oid any risk of fire.
17. The operator must NEVER weld containers that ha e pre iously
contained petrol, lubricants, gas or similar flammable materials, e en if the
container has been empty for a considerable time. THERE IS A VERY
HIGH 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.

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19. To pre ent electric shock, we strongly suggest the following rules:
20. Do not work in a damp or humid en ironment.
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.
EN 60974-1 Standard: Open-circuit oltage. During the operation of the
machine, the highest oltage, with which it is possible to come into contact, is
the open-circuit oltage between the welding clamps.
The maximum open-circuit oltage 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 wa eform and on the hazards arising from the work
place. These alues are not applicable to the strike currents and those for
stabilisation of the arc that could be abo e it.
The open-circuit oltage, for as many adjustments as possible, must ne er
exceed the alues relating to the arious cases shown in the following table:
Case
Working conditions
Open
-
circuit oltage
1 Places with increased risk of
electric shock
DC current: 113V
peak alue
AC current: 68V
peak alue and
48V effecti e
2 Places without increased risk
of electric shock
DC current: 113V
peak alue
AC current: 113V
peak alue and
80V effecti e
3 Torches held mechanically
with increased protection for
the operator
DC current: 141V
peak alue
AC current: 141V
peak alue and
100V effecti e
In case 1, the dc welding machines with rectifier must be built in such a way that,
in case of a fault de eloping in the rectifier (for example open circuit, short circuit
or lack of power), the permitted alues cannot be exceeded.
25. Before opening the machine switch off the machine and disconnect
it from the power socket.
26. Only personnel authorised by this company can carry out
maintenance on the machine.
NOTE
De ice complies with IEC 61000-3-12 with following conditions:
Short-circuit power Ssc of network in place at an interface between the user's
supply and the public network (PCC) must be least 4499 kW.
User is obliged to consult with the electricity supplier if the impedance of the
network at this point is that required short-circuit capacity Zmax = 36 mΩ and
whether the de ice can be connected with a public low- oltage network.

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On the nameplate are the following symbols: .
ELECTROMAGNETIC COMPATIBILITY
The welding de ice 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- oltage 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 de ice may be the source of interference.
Caution
We warn users, that they are responsible for possible interference from
welding.
3. TECHNICAL DATA
Method MMA - AC MMA - DC TIG - AC TIG - DC
Mains oltage V/Hz 1x230/50-60
Welding current range A 10 - 170 10 - 170 10 -200 10 - 170
Open-circuit oltage U20 V 53,0 63,0 53,0 63,0
Mains protection A 16 @ (25 @)
Max. effecti e current I1eff A 16,0 (22,5) 16,0 (16,6)
Welding current
(DC=100%) I2 ta=40 °C A 80 (110) 80 (110) 120 (120) 120(120)
Welding current (DC=60%)
I2 ta=40 °C A 100 (140) 100 (140) 140 (140) 140 (140)
Welding current (DC=x%) I2
ta=40 °C A 20%=170 (40%=170)
20%=170
(40%=170)
30%=200
(35%=200)
40%=170
(40%=170)
Protection IP23S
Standards EN 60974-1; EN 60974-10 class A
Dimensions (w x l x h) mm 130 x 430 x 230
Weight kg 8,5
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 abo e 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 abo e in brackets.

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Another option is to connect the machine to the three-phase mains 3x400 / 230V
TN-S (CS). The condition is to use a 5 pin 32 A plugs for the supply cable and
connection to the phase oltage. Black (brown) wire connected to one phase
(e.g. L1), the blue wire to the neutral wire (N) and green-yellow wire to the
grounded conductor "PE". In this case, it is possible to connect the machine to
a three-phase socket, which may be protected by fuse max. 25 A.
Attention! Do not connect to the interconnected oltage (delta oltage) (between
2 phases)!
Replacement of the plug may only be performed by Linde AG, Linde Gas
Deutschland authorized ser ice personnel.
Linde AG, Linde Gas Deutschland continuously stri es to produce the best
product possible and therefore reser es the right to change, impro e or re ise
the specifications or design of this or any product without prior notice. Such
updates or changes do not entitle the buyer of equipment pre iously sold or
shipped to the corresponding changes, updates, impro ements or replacement
of such items.
4. EQUIPMENT
CONTENT OF DELIVERY
It m No.
D scription
Quantity
5.0279 RYVAL 200 AC/DC PULSE DAVE 1
5.0278 RYVAL 200 AC/DC DAVE 1
5847 Set of Connectors for RYVAL AC/DC Da e 1
8.462.124 Quick connector Ry al 160 female 1
In case you order a torch with the connector on, the set 5756 would be used for
that purpose and will not be deli ered then. In case you order a Gas Hose, the
quick connector 8.462.124 would be used for that purpose and will not be
deli ered then.
ACCESSORIES TO ORDER
It m No. D scription
VM0321-2 Hose Gas 3m Ry al quick connector G1/4
VM0253 Welding Cable Set 2x 3m 35-50 200A
5.0508 Welders Cart P 80
17FSL4S Torch PARKER SGT 17 4m 35-50 FX S
17FSL4SUD Torch PARKER SGT 17 4m 35-50 FX S UD
17FSL8S Torch PARKER SGT 17 8m 35-50 FX S
17FSL8SUD Torch PARKER SGT 17 8m 35-50 FX S UD

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26FSL4S Torch PARKER SGT 26 4m 35-50 FX S
26FSL4SUD Torch PARKER SGT 26 4m 35-50 FX S UD
26FSL8S Torch PARKER SGT 26 8m 35-50 FX S
26FSL8SUD Torch PARKER SGT 26 8m 35-50 FX S UD
6008 Pressure Reducer FIXICONTROL Ar 2 manometers
5.0174ST Foot Pedal Remote CTRL 3 m RYVAL incl. Connector ST
5. OPERATOR CONTROLS
MAIN PARTS
Fig . 1 Main parts
Pos.
D scription
A1 Operating panel
A2 Quick connector +
A3
Gas connector of the welding torch
A4
Torch control connector
A5
Quick connector
-
A6
ON/OFF switch

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A7
Gas inlet
A8
Mains cable and plug
OPERATING PANEL
Fig. 2 RYVAL 200 AC/DC Pulse Da e
Fig. 3 RYVAL 200 AC/DC Da e
Pos. D scription
1 LED MMA
2 LED TIG LA – Lift Arc ignition

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3 Button switch MMA/TIG HF/TIG LIFT ARC.
4 LED HF. If illuminated the HF ignition was set.
5 Button switch AC/DC mode
6 LED AC
7 LED DC
8 LED Two Stroke (2T).
9 Button TIG 2T or 4T (two stroke, four stroke)
10 LED Four Stroke (4T)
11 Encoder
12 LED Pregas, 0,0 – 2,0 s
13 LED start current (just 4T), 10 – 170 A DC, 10 – 200 A AC.
14 LED Up slope, 0 – 10 s
15
LED – non pulse mode. To change, turn the encoder 11 and
confirm by means of pressing the encoder 11 down. Display 31
shows ---
16 LED Main Welding Current. 10 - 170 A (TIG-DC)；10 - 200 A
(TIG-AC)； 10 – 170 A (MMA-AC/DC)
17
LED – PULSE selected To change, turn the encoder 11 and
confirm by means of pressing the encoder 11 down. Display 31
shows -P-.
18 LED lower current, 10 – 170 A (TIG-DC)；10 – 200 A (TIG-AC)；
10 – 170 A (MMA-AC/DC).
19 LED ratio of the pulse current and the base current. 5 – 95 %. Just
for the pulse mode.
20 LED Pulse Frequency. 0,5 – 200 Hz. Just for the pulse mode.
21 LED Down Slope, 0 – 10 s
22 LED Balance (just TIG AC). Used for elimination of the aluminium
oxides. Range +5 to -5, (more in the text below).
23 LED end current, 10 – 170 A DC, 10 – 200 A AC, just in 4T.
24 LED Post Gas, 0 – 10 s.
25 LED Time (s). If illuminated there are alues in s on the display.
26 LED %. If illuminated there are alues in % on the display.
27 LED Hz. If illuminated there are alues in Hz on the display.
28 LED HOT START, just for MMA, 0 – 100. LED lights up after
pressing the encoder 11.

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29 LED welding current MMA 10 – 170 A, just for MMA. LED lights
up after pressing the encoder 11.
30 LED ARC FORCE just for MMA, 0 – 100. LED lights up after
pressing the encoder 11.
31 Display
32 LED ALARM. If illuminated there is under or o er oltage in the
mains or the machine is o erheated.
33 LED Voltage (V). If illuminated there are alues in V on the display.
34 LED current (A)
35 LED ON
6. GETTING STARTED
Getting started must be consistent with technical data and conditions of use.
GETTING STARTED MMA – COATED ELECTRODE
Fig. 4 Ways of connecting the welding cables. Follow the instructions on the
packing of the welding electrodes.
1. Insert the mains plug A8 into a suitable 1x230 V mains socket.
2. Connect the welding cables to the panel quick connectors (+) A2 and (-)
A5 according the instruction on the electrodes packing.
3. Switch the machine on by the ON/OFF switch A6.
4. Then switch to the MMA mode by means of the button 3.
5. Set the welding current by means of encoder 11. The alues will be
showed on the display.
6. Press button 5 to select AC or DC welding current.
7. It is possible to change the settings of the HOT START (increase of current
during arc ignition time), ARC FORCE (an automatic increase of the

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welding current in case the electrode touches the welding piece) by means
of the Encoder 11.
NOTE Pre ent touching the electrode any metal material for in this mode
the terminals A2 and A5 are under current.
8. Insert the coated electrode into the electrode holder, connect the clamps
of the ground cable to the welding piece and you may start welding.
GETTING STARTED TIG
Fig. 5 TIG welding set up
1. Insert the mains plug A8 into a suitable 1x230 V mains socket.
2. Fit the TIG Torch to the Panel quick connector (-) A5.
3. Connect the gas hose of the TIG torch onto Gas outlet connector A3.
4. Connect the torch control connector onto the matching connector A4.
5. Connect the work lead to Panel quick connector (+) A2.
6. Connect the gas hose to the reduction al e on the gas cylinder and on
the Gas inlet connector A7 on the rear panel.
7. Switch the machine on by the ON/OFF switch A6.
8. Press the torch trigger, the solenoid al e will open; set the desired gas
flow (pure argon).

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9. Select TIG LA or HF mode by means of switch 3. The corresponding LED
will light up.
10. Select 2T (two stroke) or 4T (four stroke) mode by means of switch
9. The corresponding LED will light up.
11. Select the method desired DC or AC method by means of the button
5. The corresponding LED will light up.
12. In the welding torch must be installed a corresponding tungsten
electrode (for AC green or golden). The electrode should be sharpened
also corresponding to the AC or DC mode.
13. Set the welding current by means of Encoder 11.
14. Other parameters may be set by means of the encoder 11. Illuminate
the appropriate LED by means of pressing the encoder 11, by means of
turning the encoder 11 set the parameter and sa e it by means of pressing
the encoder 11. After that a next LED will illuminate and you may set that
parameter the same way. The set parameter will be automatically
memorised when you mo e to another parameter of after 3 s. At e ery
turning of the encoder 11 the last selected parameter will be offered to be
changed.
15. Connect the work clamp to the work piece or at the welding table and
you can start welding.
16. The following table describes the influence setting the clearance
effect.
Clearance effect
Value
-
5 to 0
Value
+1 to +5
Shape of the current
cur e
Penetration
Deep
Shallow
Le el of wear of the of
tungsten electrode
Smaller Bigger

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REMOTE CONTROL
The RYVAL 200 AC/DC PULSE supports three kinds of remote controls.
1. TIG torch with UP-DOWN buttons
2. Foot pedal
3. Standard separate remote control for changing the alue of the welding
current.
All three models of remote controls can be connected by means of the front panel
connector A4.
Fig. 6 Foot pedal remote control
Pos.
D scription
P1
Stepping surface
P3
Connector (connect to matching connector 13 on the front panel)
1. When you connect the P3 connector to matching connector on the front
panel A4 the function setting the current from the front panel will blocked.
2. Set by the encoder 11 the maximal required alue of the current.
3. Set the machine to the mode 2T.
4. By pressing the stepping surface P1 down you start the welding process.
The alue of the welding current depends on the le el of pressing the
stepping surface. To reach the maximal current, set by encoder 11,
requires to gently pressing to the lowest position of the stepping surface
P1. The set current will be displayed on the display 31.
5. The welding process ends after releasing the stepping surface P1.

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7. TWO STROKE AND FOUR STROKE IN TIG MODE
TWO STROKE – 2T
FOUR STROKE – 4T
BILEVEL – SECOND WELDING CURRENT
When the machine is in 4T mode, there is always acti e the BILEVEL function.
The alue of the second current is automatically set to 50% of the pre-set alue
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.
Gas
Pregas Postgas
Down slope
Welding current
Current
Gas
Down slope
Post
gas
Up slope
Pregas
Welding current
Current

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8. GENERAL INFORMATION ON THE WELDING MODES
MMA w lding
The manufacturers of the electrodes specify the optimum welding current for
each type of electrode. The type of electrode to be used depends on the
thickness of the material to be welded and on its position.
Insert the chosen electrode into the electrode holder. To strike the electric arc,
rub the electrode against the material to be welded connected to the earth
(ground) clamp. Once the arc is struck, lift the electrode holder slowly to the
normal welding distance.
To strike the arc better, an initial current is supplied which is higher (hot-start)
compared to the welding current. The electrode on melting deposits in the form
of drops onto the piece to be welded and its outer coating is consumed supplying
the shielding gas for the welding. To facilitate the fluidity of the welding arc, while
the drops are coming off, which can cause a short circuit between the electrode
and the weld pool, a momentary increase in the welding current (arc-force) is
gi en, thus pre enting the arc from going out. If the electrode stays stuck to the
piece to be welded, there is an anti-stick function that, after a certain short-circuit
time, cuts off the power to the generator. Thus you can detach the electrode
without damaging it.
When the coating electrodes are used, you need to remo e the dross from the
welding after e ery pass.
TIG w lding
In TIG (Tungsten Inert Gas) welding the electric arc is struck between a non-
consumable electrode (pure tungsten or an alloy) and the workpiece in an
atmosphere protected by an inert gas (argon).
The TIG lift-arc process is struck by contact. A low short-circuit welding current
is set to limit the tungsten inclusion on the workpiece. This process does not
guarantee a weld of high quality at the start of the bead.
To completely pre ent the tungsten being included, you must not let the
electrode touch the piece to be welded. Howe er you use a start-up with high
frequency (HF) discharge that allows striking of the electric arc at a distance.

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9. 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 en ironment.
 WARNING Disconnect the RYVAL from the mains supply oltage before
disassembling.
2. 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  Do not blow air into the welder during cleaning. Blowing air into
the welder can cause metal particles to interfere with sensiti e electronic
components and cause damage to the welder.
3. To clean the welder, disconnect it from the mains supply oltage then open
the enclosure and use a acuum cleaner to remo e any accumulated dirt
and dust. The welder should also be wiped clean. If necessary, sol ents
that are recommended for cleaning electrical apparatus may be used.
4. Troubleshooting and repairing of RYVAL welding equipment should only
be carried out only by suitably qualified or competent person.
5. A ‘competent person’ must be a person who has acquired through training,
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.
6. The person carrying out the ser icing needs and repairs must know what
to look at, what to look for and what to do.
10. 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 ser ice personnel or with prior written
consent obtained from Linde AG, Linde Gas Deutschland Ser ice
Department.

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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 ser ice manual.
11. Within this operating manual are details regarding the maintenance
necessary to ensure trouble free operation.
NOTE  Warranty repairs must be performed by either a Linde AG, Linde Gas
Deutschland Ser ice Centre, a Linde AG, Linde Gas Deutschland distributor or
an Authorised Ser ice Agent appro ed by the company Linde AG, Linde Gas
Deutschland.
11. DISPOSAL
Only for EU countries. Do not dispose of electric tools together with
household waste material.
In accordance with European Council Directi e 2002/96/EC on
electrical and electronic equipment waste and its implementation in accordance
with national law, electric tools that ha e reached the end of their ser ice life
must be collected separately and returned to an en ironmentally compatible
recycling facility.