Linde RYVAL 200 MIG MAN PFC User manual

Linde AG, Linde Gas Deutschland. © Ryval 200 MIG MAN PFC Manual EN 04
WELDING MACHINE
RYVAL 200 MIG MAN PFC
OPERATING MANUAL

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CONTENT
1. INTRODUCTION ....................................................................................... 3
2. SA ETY INSTRUCTIONS AND WARNINGS ............................................ 4
3. TECHNICAL DATA .................................................................................... 6
4. EQUIPMENT ............................................................................................. 7
5. OPERATOR CONTROLS .......................................................................... 8
6. GETTING STARTED MIG/MAG .............................................................. 12
7. GETTING STARTED TIG ........................................................................ 18
8. GETTING STARTED MMA ...................................................................... 19
9. ROUTINE MAINTENANCE & INSPECTION ............................................ 19
10. STATEMENT O WARRANTY .............................................................. 20
11. DISPOSAL ............................................................................................. 21

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1. 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.
The model of RYVAL 200 MIG MAN P C is the multi-function inverter power
generators welding by those methods
a) MIG/MAG in 2T, 4T, wires SG2 or stainless steel 0,6 - 1,0 mm, Al
wires 1,0 mm, flux cored wires shelf shielding or standard.
b) E – (MMA) coated electrodes up to 4,0 mm
c) TIG lift arc
RYVAL 200 MIG MAN P C is equipped by system of Power actor Correction
P C) – which enables operating on AC power supply of 95V – 270V.
What are the advantages of PFC solution?
1. Higher efficiency and less stress related to the circuit breaker (in other
words, circuit breaker will switch off later than the devices without P C)
2. The machine can be connected to the mains 110 V - 230 V + -15% Small
influence of under voltage and overvoltage mains power
3. Smaller level of electromagnetic interference
4. Minimum net reactive current loading

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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 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. He 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. THERE IS A VERY
HIGH RISK O EXPLOSION.

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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:
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 58V.
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.

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30. Only personnel authorised by this company can carry out maintenance
on the machine.
NOTE:
Device complies with IEC 61000-3-12.
ELECTROMAGNET C COMPAT B L TY
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.
3. TECHNICAL DATA
Method MIG/MAG MMA TIG
Mains voltage V/ z 1x230/50-60
Welding current range A 25 - 200 10 - 200 10 - 200
Open-circuit voltage
U20 V 68
Mains protection A 16 @
Max. effective current
I1eff A 15,8 16,0 13,2
Welding current
(DC=100%) I2 A 140 120 150
Welding current
(DC=60%) I2 A 170 140 180
Welding current
(DC=x%) I2 A 35%=200 30%=200 40%=200
Protection IP 23S
Standards EN 60974-1; EN 60974-10 class A
Dimensions (w x l x h)
generator mm 251x540x395
Weight kg 16,5
Linde AG, Linde Gas Deutschland continuously strives to produce the best

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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.
4. EQUIPMENT
MODELS
tem No Description
5.G-19 RYVAL 200 MIG MAN P C
ACCESSOR ES TO ORDER
tem No. Description
VM0253 Welding Cable Set 2x 3m 35-50 160A
5.0156 Roll 0.6-0.8/1.0 RYVAL MIG
4281 Valve Red.AR /CO2, 2 manometers,MINI
S777a Light Reactive Welding Helmet S777a GRAY
5950 Set SGT, SR 17/18/26d=1,6
5951 Set SGT, SR 17/18/26d=2,4
5952 Set SGT, SR 17/18/26d=3,2
700.0306.10 Electrode wolf.1.6x175-Violet
700.0308.10 Electrode wolf.2.4x175-Violet
700.0310.10 Electrode wolfram E3 3.2x175 - violet
SGB25-3 Torch PARKER SG 250 3m (MIG/MAG)
SGB25-4 Torch PARKER SG 250 4m (MIG/MAG)
SGB25-5 Torch PARKER SG 250 5m (MIG/MAG)
17 SL4ST Torch PARKER SGT 17 4m 35-50 X ST (TIG)
5756 Set Connectors RYVAL 200 MIG P C
VM0321-3 Hose Gas 3m RYVAL
4314 Quick connector RYVAL 160/40

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5. OPERATOR CONTROLS
ig. 1. RYVAL 200 MIG MAN P C
Pos. Description
1 Control panel
2 Handle
3 Gas connector for TIG torch
4 (-) terminal of welding cables
TIG torch connector
5 Central MIG/MAG torch connector
6 TIG torch control connector
7 (+) terminal of welding cables
8 Gas connector
9 Spool holder
10 Secondary control panel (see details below)
11 Terminals of change polarity MIG / MAG torch
12 Wire feeder

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ig. 2 – Control panel
Pos. Description
13 LED. If it lights the mode 4 stroke has been selected by the button
15.
14 LED. If it illuminates the mode 2 stroke has been selected by the
button 15.
15 Button for selecting the 2T or 4T mode.
16 LED TIG
17 LED MMA
18 LED MIG/MAG
19 Button for selecting the welding method.
20 Display
21 LED. If it lights the display 20 shows welding current
22 LED. If it lights the display 20 shows the wire feed speed
23 Display
24 LED. If it lights the display 23 shows the time of down slope
25 LED. If it lights the display 23 shows the voltage
26 LED. If it lights display 23 shows the value of ARC ORCE

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27 LED. If it lights the thermo-switch is disconnected. In such a case
leave the machine on to cool down.
28 LED. If it lights the machine is switched on by the main switch
29 Choke potentiometer
30
Potentiometer:
• Voltage for MIG/MAG MAN,
• ARC ORCE for MMA
• Down Slope for TIG
31
Potentiometer:
• Wire speed feed (MIG/MAG)
• Current for MMA and TIG
ig. 3 Secondary control panel – panel in the space of the wire feeder
Pos. Descriptions
32 Switch Remote. ON – on the remote control
O – of the remote control
33 Switch Spool Gun. In the ON position one can weld with the Spool
Gun
34 Potentiometer for the Burnback time setting
35 Potentiometer for the initial wire speed setting
36 Potentiometer for the Pre Gas time setting

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37 Potentiometer for the Post Gas time setting
38 Gas setting button
39 Wire feeding button
W RE FEEDER
ig. 4 Wire feeder
Pos. Description
E1 Nut of pressure arm
E2 Pressure arm
E3 Inlet liner
E4 EURO connector
E5 Roll
OVERV EW OF ROLLS FOR W RE FEED
ab
a = 22 mm
b = 30 mm
Groove type Wire diameter Item No
Steel
0,6-0,8 2187
0,8-1,0 2188
Aluminum
0,8-1,0 2270

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lux core
0,8-1,0 2318
1,0-1,2 2319
6. GETTING STARTED MIG/MAG
Getting started must be consistent with technical data and conditions of use.
CHOOS NG THE FEED NG ROLL
In all machines (Linde AG, Linde Gas Deutschland MIG / MAG) rolls with two
grooves are used. These grooves are intended for two different wire diameters
(e.g. 0,8 and 1,0 mm).
Rolls for wire feed must comply with the diameter and material of the welding
wire. Only this way a smooth wire feed can be achieved. Irregularities of the
wire feed leads to a poor quality of welding and deformation of the wire.
∅ 1,0
1,0 1,20,8
ABC
ig. 5 The influence of the roll groove on the welding wire
NSERT NG THE W RE
1. Open the side cover of the wire feeder space
2. Put the wire spool on the wire spool holder D1 and fix it with the fixing nut
D2.
3. Cut off the curved or damaged end of welding wire and lead it through
the inlet liner E3, and the roll into the liner inside the EURO torch
connector (about 5 cm). Make sure, that you use the suitable groove.
4. Put the pressure arm E2 down in that way, that the teeth or the gear fit
and fix it by setting the lever E1 into vertical position.
5. Adjust the pressure nut that way that it provides constant movement of
wire but it does not deform wire. The adjusting screw is located under the
plastic screw E1.
6. The spool brake is set by the manufacturer. If necessary, the brake can
be adjusted by a screw D1 so that while stopping the feed, spool will be
stopped on time (it will avoid excessive release of wire).However, too
A Correct
B Wrong
C Wrong

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tight brake needlessly strains the feeding mechanism and thus slippage
may occur in the wire rolls.
ig. 6 Spool holder
NSERT NG THE W RE TO THE TORCH AND CONNECT ON OF GROUND
CABLE
ig. 7 Connecting the ground cable and the torch
1. Connect the torch B6 to connector B8 on the machine while the machine is
turned off.
2. Connect the ground cable to the terminal of welding cables (-) B4
Pos. Description
D1 Spool Holder
D2 Nut Spool Holder
D3 It is not for this welder

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3. Connect the groung clamps B5 to the welder B7 or to the welding table.
Notice When inserting the wire do not point with torch to the eyes!
4. Remove the gas nozzle from the torch
5. Unscrew the current nozzle
6. Connect the machine to power supply
7. Turn the main switch on the back panel to ON
8. Press the button 19 to select the mode MIG/MAG
9. Press the button 15 to select 2T or 4T.
10. Press the button 39. The welding wire is fed into the torch. After coming
off from the torch tube, screw the current nozzle and gas nozzle on.
11. Before welding, spray the area in a gas hose and current nozzle with a
separation spray, to prevent damage.
ADJUSTMENT OF GAS FLOW
The electric arc and the weld must be perfectly shielded by gas. Too small
amount of gas does not perform the protective atmosphere and on the other
hand to big amount of the gas brings air into the electric arc.
Notice Gas bottle must be well secured against fall. This manual does
not solve the safe securing of gas bottle. Information can be obtained from a
supplier of industrial gases.
1. Connect the gas hose to gas outlet F8 on the valve and the gas inlet to the
gas connector 8.
2. Press the button 38.
3. Turn the adjusting screw F7 at the bottom side pressure reducing valve,
until the meter F6 shows the required flow, then release the button. The
optimum flow is 10-15l/min.
4. After long-term shutdown of the machine or replacement of the torch it is
suitable to blow the pipes with protective gas before welding.
ig. 8 - Gas flow setting

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Pos. Description
1 Gas bottle
2 Cylinder Valve
4 Pressure Reducer
5 High Pressure Manometer
6 Low Pressure Manometer
7 Adjusting Screw
8 Gas outlet
ADJUST NG WELD NG PARAMETERS FOR M G MAN
1. Approximate setting for the MIG / MAG welding current and voltage
corresponds the empirical relationship U2 = 14 +0.05 I2. According to
this relationship, we can determine the required voltage. When setting
the voltage, we expect the decline in voltage during load. The voltage
drop is approximately 4.5-5.0 V at 100 A.
2. By means of the potentiometer 30 select voltage.
3. Then by means of the potentiometer 31 select the appropriate wire
speed.
4. By means of the potentiometer 29 tune the arc by changing the levels of
the choke.
Wire diameter (mm) Welding current (A) Material thickness (mm)
0,6 25 - 110 1,0 - 1,6
0,8 35 - 160 1,0 - 2,3
0,9 45 - 160 1,0 - 2,3
1,0 45 - 200 1,2 - 7,0
Table of approximate parameter settings
ADJUST NG THE MACH NE FOR ANOTHER W RE D AMETER
In all machines Linde AG, Linde Gas Deutschland MIG / MAG are used rolls
with two grooves. These grooves are intended for two different wire diameters
(e.g. 0,8 a 1,0 mm). Groove can be replaced by removing the rolls and rotating
them, or use a different roll grooves with required dimensions.
1. Open the nut E1 to the right, pressure roll E2 will be opened upward
2. Unscrew the plastic locking element E5 and remove the roll
3. If there is a suitable groove on the roll, rotate the roll and place it back on
the shaft and secure it by screwing the element E5.

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FLUX CORE W RE – SETT NG THE POLAR TY FOR M G/MAG TORCH
1. It is desirable to have positive polarity on the MIG/MAG torch while welding
with solid wire in majority of cases. The welder is supplied from the
production with positive polarity on the MIG/MAG torch.
2. or welding with flux cored wires it may be necessary to have negative
polarity on the MIG/MAG torch.
3. The middle terminal K3 is connected to the central euro connector of the
MIG/MAG torch. We supply the welder with K3 connected to (+) K1.
4. In case of welding with flux core wire with (-) polarity, connect K3 by means
the bridge K2 with K4 terminal. Use Phillips screwdriver.
5. Make sure you fasten the terminals properly.
6. Connect the ground cable to the (+) panel socket, fig. 1, pos. 7.
ig. 9 Terminals for changing the polarity of the MIG/MAG torch
Pos. Description
K1 Upper terminal (+)
K2 Bridge
K3 Middle terminal
K4 Lower terminal (-)

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ADJUST NG THE MACH NE FOR WELD NG OF ALUM N UM
or feeding the AL wire it is necessary to use roll with the “U” profile - see
paragraph OVERVIEW ROLLS WIRE EED. To prevent problems with feeding
use wires with diameter. 1.0 mm of AIMg3 or AlMg. Wire of alloy Al99, 5 or
AlSi5 are too soft and easily will cause problems with movement.
or the aluminum welding it is also necessary to provide the torch tefl. liner and
special current nipple. We do not recommend you to use the torch longer than
3 m. Great attention must be paid to adjust the contact power of rolls – it must
not be too high, otherwise there is a deformation of the wire.
As a protective atmosphere is necessary to use argon.
ig. 10 Customization of the feed for the aluminium wire
Pos. Description
G1 EURO connector
G2 Rolls
G3 Liner terminal for 4,0mm, 4,7mm outer diameter
G4 O-ring 3,5 x1, 5mm to prevent escape of gas
G5 Nut
G6 Liner tefl.
G7 Sustain pipe for teflon and plastic liner

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7. GETTING STARTED TIG
Getting started must be consistent with technical data and conditions of use.
ig. 11 Connecting the ground cable and the torch
1. Connect the torch B12 to the terminal of welding cables (-)B13, to the gas
connector B14 and connector B10.
2. Connect the ground cable to the terminal of welding cables (+) B9 and the
ground clamps B11 to the welder B7 or to the welding table.
3. Connect the machine to power supply and turn the main switch on the
back panel to ON.
4. Connect the gas hose and gas flow adjustment described in 6.4
ADJUSTMENT O GAS LOW
5. Press the button 19 to select the mode TIG .
6. Use the potentiometer 31 to adjust the welding current.
7. Use the potentiometer 30 to adjust the time of Slope down.
8. By means of the potentiometers 36 you can change the time of Pre Gas.
9. By means of the potentiometers 37 you can change the time of Post Gas.

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BAS C SETT NGS FOR T G WELD NG – STA NLESS STEEL, DC
CURRENT
Material
thickness
mm
Tungsten
electrode
diameter
mm
iller material
diameter mm
Welding
current
A
Argon flow
l/min
Gas
nozzle mm
1 1 1,5 40-60 3 10
1,5 1,5 1,5 50-90 4 10
2 2 2 80-100 4 12
3 2-3 2-3 90-140 5 12
4-5 3-4 3-4 110-180 5 12
8. GETTING STARTED MMA
Getting started must be consistent with technical data and conditions of use.
1. Connect the electrode holder and the work lead to terminals B13 and B9
according the instructions on the electrode package.
NOTE Prevent touching the electrode any metal material for in
this mode the terminals B13 and B9 are under current.
2. Press the button 19 to select the mode MMA .
3. To select the current use the potentiometer 31.
4. It is possible to change the level of ARC ORCE by means of the
potentiometer 30.
. 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.
2.  WARNING Disconnect the Ryval from the mains supply voltage
before disassembling.
Special maintenance is not necessary for the control unit parts in the
Welder. If these parts are damaged for any reason, replacement is
recommended.
3. CAUTION 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.

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4. 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.
5. Troubleshooting and repairing of Ryval welding equipment should only be
carried out only by suitably qualified or competent person.
6. 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.
7. The person carrying out the servicing 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 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. ailure 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