Linde Ryval 400 aXe User manual

Linde AG, Linde Gas Deutschland © Ryval 400-500 aXe MANUAL EN 02
MIG/MAG WELDING MACHINES
Ryval 400 aXe
Ryval 500 aXe
MINOR2 - MAJOR – SYNERGY
BASIC
INS RUC ION MANUAL

2 29
Linde AG, Linde Gas Deutschland ©
Content:
1. INTRODUCTION ............................................................................................. 3
2. SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 4
3. CONDITIONS OF USE ...................................................................................... 7
4. TECHNICAL DATA ........................................................................................... 8
5. ACCESSORIES ............................................................................................... 10
6. DESCRIPTION OF THE APPLIANCE ................................................................. 11
7. GETTING STARTED ....................................................................................... 18
8. WELDING ..................................................................................................... 23
9. ROUTINE MAINTENANCE INSPECTION ...................................................... 27
10. STATEMENT OF WARRANTY ........................................................................ 28
11. DISPOSAL ..................................................................................................... 29

3 29
Linde AG, Linde Gas Deutschland ©
1. IN RODUC ION
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 400 500 aXe are three phase sturdy welding machines for MIG MAG
welding.
The machines are designed to produce maximum power output combined
with high reliability and efficiency.
The users interface is as simple as possible; however, there are secondary
parameters that can be set from the main front panel if suitable. All of them
are available in compact models, Ryval 400 and 500 can be ordered also as
sets consisting of the generator, interconnection cable bundle and separate
wire feeding unit. We will refer to the MINOR2-MAJOR and SYNERGY
controls as DIGITAL. The appliances can be both gas cooled or water
cooled.
CONTROL MODEL
BASIC
MINOR
2
MAJOR
SYNERGY
A + V meter
optional
NO
YES
YES
Wire initial speed (Soft Start)
NO
NO
Y
ES
YES
Advice of the parameter settings
NO
NO
NO
YES
Electronic feedback of the wire
speed
NO YES YES YES
2 stoke 4 stroke
YES
YES
YES
YES
Adjustable Post and Pre Gas
time
NO YES YES YES
Spot and Interval welding
YES
YES
YES
YES
Adjustable Burn Bac
k Time
NO
YES
YES
YES

4 29
Linde AG, Linde Gas Deutschland ©
2. SAFE Y INS RUC IONS AND WARNINGS
1. OPERATION AND MAINTENANCE OF WELDING EQUIPMENT CAN BE
DANGEROUS AND HAZARDOUS TO YOURHEALTH.
2. Arc welding produces intense electric and magnetic emissions that may
interfere with the proper function of cardiac pacemakers, hearing aids, or
other electronic health equipment. Persons who work near arc welding
applications should consult their medical health professional and the
manufacturer of the health equipment to determine whether a hazard
exists.
3. Once the packing has been opened, make sure that the machine is not
damaged. If in any doubt, call the service centre.
4. This equipment must only be used by qualified personnel.
5. During installation, any electric work must only be carried out by trained
personnel.
6. The machine must be used in a dry place with good ventilation.
7. 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.
8. It is prohibited to connect more than one generator in series or in parallel.
9. When installing the machine, follow the local regulations on safety.
10. The position of the machine must allow easy access by the operator to
the controls and connectors.
11. When the welding machine is operating, all its covers and doors must
be closed and well fixed.
12. Do not expose the welding machine to direct sunlight or to heavy rain.
This equipment conforms to protection rating IP23S.
13. 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 cutting.
14. 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 arc 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.
15. 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.
16. Keep all fumes and gases from the breathing area.
17. Keep your head out of the fume plume.
18. Use an air-supplied respirator if ventilation is not adequate to remove
all fumes and gases.
19. The kinds of fumes and gases from the plasma arc depend on the kind
of metal being used, coatings on the metal, and the different processes.
You must be very careful when welding any metals which may contain one

5 29
Linde AG, Linde Gas Deutschland ©
or more of the following:
Antimony Chromium Mercury
Nickel
Cobalt
Arsenic
Barium
Copper
Selenium
Beryllium
Lead
Silver
Cadmium
Manganese
Vanadium
20. Always read the Material Safety Data Sheets (MSDS) that should be
supplied with the material you are using. These MSDSs will give you the
information regarding the kind and amount of fumes and gases that may
be dangerous to your health.
21. 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.
22. Noise can cause permanent hearing loss. Welding arc processes can
cause noise levels to exceed safe limits. You must protect your ears from
loud noise to prevent permanent loss of hearing.
23. To protect your hearing from loud noise, wear protective ear plugs
and or ear muffs. Protect others in the workplace.
24. Noise levels should be measured to be sure the decibels (sound) do
not exceed safe levels.
25. The operator must ensure all flammable materials are removed from
the work area to avoid any risk of fire.
26. 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 OF EXPLOSION.
27. The operator must be aware of all the special regulations which he
needs to conform to when cutting in enclosed spaces with a high risk of
explosion.
28. To prevent electric shock, we strongly suggest the following rules:
a) Do not work in a damp or humid environment.
b) Do not use the machine if its cables are damaged in any way.
c) Make sure that the earthing system of the electric equipment is
correctly connected and operational.
d) The operator must be insulated from the metal components
connected to the return wire.
e) The earthing of the piece being worked could increase the risk of
injury to the operator.
29. 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 clamps.
30. The maximum open-circuit voltage of the plasma machines is

6 29
Linde AG, Linde Gas Deutschland ©
established by national and international standards (EN 60974-1)
depending on the type of 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.
31. 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
4 Plasma cutting DC current: 500V
peak value
32. In case 1, the dc 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
33. Before opening the machine switch off the machine and disconnect it
from the power socket.
34. Only personnel authorised by this company can carry out maintenance
on the machine.
PRO EC IVE U ILI IES
1. Welding helmet with filter shade at least 10
2. Welding gloves
3. Welding apron and cloth
4. Welding boots
RISK OVERVIEW
1. Risk of electric shock.
2. Ultraviolet light and light radiation
3. Risk of inhaling gas fumes and dust particles
4. Burns

7 29
Linde AG, Linde Gas Deutschland ©
5. Noise
NO E
1. It is forbidden to operate a machine with damaged insulation of the
welding torch or supply cable.
2. Never operate the machine taken down or damaged covers.
3. It is forbidden to operate the machine in wet environments and outdoors
in rain or snow.
4. Ensure proper grounding clamping pliers, which also reduces the risk of
electric shock.
5. Use prescribed protective utilities, keep them dry.
6. Arc welding produces intense electric and magnetic emissions that may
interfere with the proper function of cardiac pacemakers, hearing aids,
or other electronic health equipment. Persons who work near plasma
arc cutting applications should consult their medical health professional
and the manufacturer of the health equipment to determine whether a
hazard exists.
7. Never aim the torch against the eyes, body or other person.
3. CONDI IONS OF USE
1. This equipment must only be used by qualified personnel.
2. During installation, any electric work must only be carried out by trained
personnel.
3. Device complies with IEC 61000-3-12.
4. Do not expose the plasma machine to direct sunlight or to rain or snow.
This equipment conforms to protection rating IP23S.
5. Place the machine the way that the cooling air can enter the vents without
restriction to. It is necessary to ensure that no impurities, especially metal
particles, are not drawn into the machine.
6. Welding machine in terms of interference suppression is intended
primarily for industrial premises. In the case of use of other areas may be
need for special measures (see EN 60974-10).
7. The machine must be protected against
a) moisture and rain and snow
b) mechanical damage
c) draft and any ventilation of neighbouring machine
d) excessive overloading - crossing technical parameters
e) rough handling

8 29
Linde AG, Linde Gas Deutschland ©
ELEC ROMAGNE IC COMPA IBILI Y
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.
4. ECHNICAL DA A
Ryval 400 Ryval 500
Mains voltage V Hz 3x400 50 3x400 50
Mains protection A 20 @ 32 @
Max. input power I1 A 28,8 45,0
Max. effective current I1eff A 15,8 22,5
Welding current range A 55 - 420 70 - 530
Open-circuit voltage U20 V 19,3 - 48,0 20,2 - 59,8
Welding current (DC=100%) I2 A 260 330
Welding current (DC=60%) I2 A 300 390
Welding current (DC=x%) I2 A 30%=420 25%=530
Voltage steps 2 x 10 3 x 10
Insulation class F F
Protection IP 23S IP 23S
Standards EN 60974-1, EN 60974-10 cl. A
Dimensions (w x l x h) mm 572x875x874 572x875x874
Weight compact GAS kg 120 155
Weight compact H2O kg 137 166
Weight Generator GAS kg 113 151
Weight Generator H2O kg 133 161
Wire speed Compact m min 1 - 19 1 - 19
Spool diameter Compact mm 300 300
Spool weight Compact kg 18 18
Cooling unit
Cooling power (Q=1l min) kW 0,74
Total liquid content l 3,5
Max. pressure Bar 3,5

9 29
Linde AG, Linde Gas Deutschland ©
Max. flow l min 8
Feeding unit PS aXe
Wire speed m min 1 - 19
Input voltage U1 V Hz 24 1~50
Input current I1 A 4
Welding current I2 (DC=100%) A 320
Welding current I2 (DC=60%) A 400
Spool diameter mm 300
Spool weight kg 18
Protection IP 23S
Dimensions (w x l x h) mm 264x704x507
Weight (without wire and torch) Kg 22
Standards EN 60974-5
Feeding unit FANFEED 40W SNEIL
Wire speed m min 1 - 25
Input voltage U1 V Hz 24 1~50
Input current I1 A 4
Welding current I2 (DC=100%) A 320
Welding current I2 (DC=60%) A 400
Spool diameter mm 300
Spool weight kg 18
Protection IP 21S
Dimensions (w x l x h) mm 245x700x450
Weight (without wire and torch) Kg 18
Standards EN 60974-5

10 29
Linde AG, Linde Gas Deutschland ©
5. ACCESSORIES
DELIVERED WI H HE MACHINE
1. Earthing cable 3m with a clamp
2. Feed roll 1,0 - 1,2mm
3. Gas hoses
4. By pass hose (just for H2O models)
5. Reduction for the wire spool
ACCESSORIES O ORDER
1. Wire cleaner
2. CO2 Gas pre heating cable
3. Reduction valve KU 5, K 2
4. Gas cylinder
5. Torch consumables
6. Earthing cable 4 - 5 m
7. Feed rolls 0,6-0,8 1,0-1,2 1,4-1,6 for carbon steels, aluminium, flux
core wires
8. Torches with UP-DOWN remote control
9. Welding torches (see the table below)
Torch type
Cooling
MB 36
KD
Gas
MB 501 D
H2O

11 29
Linde AG, Linde Gas Deutschland ©
6. DESCRIP ION OF HE APPLIANCE
MAIN PAR S
Fig. 1 - Main parts of Ryval compact aXe

12 29
Linde AG, Linde Gas Deutschland ©
Fig. 2 - Main parts of Ryval Separate aXe
A1
On Off Switch
A2
Switch coarse
A3
Switch smooth

13 29
Linde AG, Linde Gas Deutschland ©
A4
Quick Connectors L1, L2, L3
A6
PCB control panel
A7
EURO connector
A8
Wire Feeder
A9
Spool Holder
A10
Solenoid Valve
A11
Mains Cable
A12 Feeder Holder Feeder
A13
Feede
r Holder Generator
A14
Quick Connector
A15 Connector female
A16
Connector male
A17
Quick Connector male
A18 Clamp for the cable Bundle
A19
Clamp for the cable Bundle
A20
Cable Bundle Inlet Feeder
A21 Cable Bundle
A22
Cable Bundle Generator
A23
LE
D ON Indicator
A26
Adaptor W (red)
A27
Adaptor W (blue)
A30
CU aXe Cooling unit
A31
Cup
A32
Adaptor W (red)
A33
Adaptor W (blue)
CON ROL PANEL - OVERVIEW
Fig. 3 - Ryval 500 aXe control panel
V1 PCB - encoder
V2
ON OFF
Switch
V3
Switch coarse

14 29
Linde AG, Linde Gas Deutschland ©
V4
Switch smooth
DIGI AL CON ROL PANEL MINOR2-MAJOR-SYNERGY
Fig. 4 – MINOR2-MAJOR-SYNERGY digital control panel
Pos.
Symbol
Description
X1
Button
 Wire insertion

default RESET (toget
her with button
X2
)
X2
Button
 Gas test

default
RESET (together with button
X1
)
X3
Button
 Switches between 2S or 4S,
 Press more than 3s will initiate spot or interval
mode
 Enters secondary parameters (together with
button X5
)

15 29
Linde AG, Linde Gas Deutschland ©
X4 Green LED 2 Stroke
X5
Button
 In MANUAL disabled
 In SYNERGY switches among A, wire speed or
material thickness
 Enters secondary parameters (together with
button X3)
X6
Green LED – lights if on the display X8 are displayed
Amperes (required setting), (just SYNERGY).
X7
Green LED - lights if on the display X8 is displayed
Wire Speed in m min (required setting), (just
SYNERGY).
X8
Left Display X8, shows:
 Amperage (real or required)
 Wire speed
 Material thickness
 Program No
 Secondary parameters:
- ISP – initial speed (soft start) [%]
- PrG – Pre gas time [s]
- PoG – Post gas time [s]
- brn – Burn back time [s]
- SPo – Time of tack welding [s]
- Int - Time of interval [s]
X9 LED - Cooling circuit error
X10 LED - Lights after finishing welding and signals the
HOLD function of A+V (last measured parameters)
X11
LED - Thermal overheating. Leave the machine on to
cool down by means of the fans.
X12
Right Display
 Voltage (real)
 Values of the secondary parameters

Switches and choke settings (Just SYNERGY)
X13
Position of the coarse switch (just SYNERGY)
X14
Position of the smooth switch (just SYNERGY)
X15
Position of the choke (just SYNERGY)
X16 LED – The mode of selecting the program is active
(
just
SYNERGY).
X17
Green LED – lights if on the display X8 is displayed
material thickness, (just SYNERGY).

16 29
Linde AG, Linde Gas Deutschland ©
X18 LED - 4 Stroke
X19
LED
 When flashes, the interval welding mode has
been selected
 When illuminated, the spot welding mode has
been selected
X20
Encoder
 Sets wire speed (all models) , Amperage or
material thickness (just SYNERGY)
 Selects program No (just SYNERGY)

Sets secondary parameters
BASIC CON ROL PANEL
Fig. 5 – BASIC control panel
V2
On Off Switch
V3
Switch Coarse
V4 Switch Fine
V5
Wire speed
V6
Spot time
V7
Interv
al time
V8
LED ON
V9
LED thermal protection
V10 Switch 2T 4T (optional)
V11
Wire insertion
V12
Gas test
V13
A meter (optional)

17 29
Linde AG, Linde Gas Deutschland ©
V14
V meter (optional)
V15
LED over heating
WIRE FEEDER
Fig 6 – Wire feeder 4 rolls, 2 rolls
Po
s
.
Description
E1
Fixing shaft
E2 Pressure arm
E3
Liner
-
Feeder
E4
EURO connector
E5 Roll, Plastic cup

18 29
Linde AG, Linde Gas Deutschland ©
ab
4
-
ro
lls
a = 32 mm
b = 40 mm
Grove type Wire diameter Item No.
Steel
0,6
-
0,8
1657
0,8
-
1,0
2150
1,0
-
1,2
2062
1,4
-
1,6
1656
Aluminium
0,8
-
1,0
2239
1,0
-
1,2
1829
1,2
-
1,6
2313
Flux core
0,8
-
1,0
2297
1,0
-
1,2
2298
1,2
-
1,4
2299
1,4
-
1,6
2534
7. GE ING S AR ED
Fig 7 – Earthing cable connecting
C1
Quick Connector Male
C2
Earthing Clamp

19 29
Linde AG, Linde Gas Deutschland ©
C3
Quick Connector
-
C4
Quick Connector
-
-
C5
Quick connector
-
--
1. Connect the quick connector C1 into C3 or C4 or C5 (according the
welding current).
2. Connect the earthing clamp C2 to the welding piece
1. In case your appliance is a model with separate wire feeder connect the
feeder with the generator by means of cable bundle A21.
2. Plug the mains plug to 3x400 V mains.
3. Switch the machine on by the ON OFF switch A1
4. There will appear type of the machine and software version on the
displays for ca 3 s time – not on BASIC.
5. Then the machine will enter the manual program (P0) and on the left
display will be the wire speed in m min (or the last parameters of previous
settings). On the right display will appear symbol --- (in manual P0
program) or the recommended settings (in programs P1 – P9) - not on
BASIC
INSER ING HE WIRE
Fig. 8 – Spool holder
1. Open the side cover of the wire feeder space
2. Put the wire spool on the wire spool holder D1 using the adapter D3 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.
D1 Spool Holder
D2
Nut Spool Holder
D3
Adapter

20 29
Linde AG, Linde Gas Deutschland ©
INSER ING HE WELDING WIRE IN O HE WELDING ORCH
Fig. 9 – Welding torch connecting
B1
EURO connector
B2
EURO connector male
B3
Torch
B4
Quick connector
W (red)
B5
Quick connector
W (blue)
B6
Quick connector
torch W (red)
B7
Quick connector
torch W (blue)
1. Connect the torch B3 to the EURO connector B1 on the
2. In case you are using the water cooling torch, connect B4 to B6 and B5
to B7
3. In case you are using water cooled model of Ryval with gas cooled torch,
you most bridge B4 and B5 by means of the by pass hose.
4. It is recommended to use torches form 2 up to 5 m long.
5. Take off the torch gas cup
6. Take off the torch tip
7. Press the button inlet wire X1 for digital, V11 for BASIC
8. When the wire reaches the end of the torch, release the button X1/V11,
screw on the tip and open nozzle.
CHANGING HE WIRE FEEDER ROLL
1. Every wire feeding roll in Linde AG, Linde Gas Deutschland machines can
be used for two different diameters of welding wire – the rolls have two
grooves.
2. When the machine is equipped with two roll wire feeder move the lever E1