Masterweld 321 HDP User manual

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MasterWeld 321 HDP
Instruction manual
GB

17/03/2014 v2.2
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1INTRODUCTION .....................................................................4
2FRONT PANEL .......................................................................4
3REAR PANEL .........................................................................5
4INSTALLATION ......................................................................5
4.1 UNIT ASSEMBLY....................................................................5
4.2 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK.6
4.3 WIRE SPOOL POSITIONING .................................................6
4.4 POSITIONING THE WIRE IN THE WIRE FEEDER................6
4.5 CONNECTIONS TO SOCKETS..............................................7
5USER INTERFACE .................................................................9
6UNIT POWER-UP..................................................................11
7RESET (LOAD FACTORY SETTINGS)................................11
7.1 PARTIAL RESET...................................................................11
7.2 TOTAL RESET ......................................................................11
8SET-UP (INITIAL SET-UP OF THE WELDING POWER
SOURCE) ..............................................................................12
COOLER ACTIVATION ....................................................................12
REMOTE CONTROLLER SELECTION ...........................................12
ADJUSTMENTS BLOCK SELECTION.............................................12
PUSH PULL ......................................................................................12
SELECTION OF BURN TYPE..........................................................12
8.1 LOCKING PROCEDURE.......................................................13
Enabling ............................................................................................13
Disabling ...........................................................................................13
8.2 TORCH LOADING.................................................................14
9ALARMS MANAGEMENT ....................................................14
AL. HEA. ...........................................................................................14
AL. COO. ..........................................................................................14
Err. C0...............................................................................................14
Err. C1...............................................................................................14
Err. C2...............................................................................................14
Err. C4...............................................................................................14
Err. C11.............................................................................................14
Err. C12.............................................................................................14
10 PARAMETERS ACTIVATION...............................................15
Working voltage ................................................................................15
Welding inductance...........................................................................15
Wire feed rate ...................................................................................15
Welding current.................................................................................15
Thickness..........................................................................................15
Programs ..........................................................................................15
Hot Start............................................................................................15
Crater Filler .......................................................................................15
3 Levels Slope ..................................................................................15
Soft Start ...........................................................................................15
Motor Slope.......................................................................................15
Bourn Back .......................................................................................15
Post gas time ....................................................................................15
Pre gas time......................................................................................15
10.1 WELDING PARAMETERS ....................................................16
11 WELDING SETTINGS...........................................................17
11.1 MIG/MAG WELDING.............................................................17
11.1.1 SETTING MIG/MAG PARAMETERS (MAIN WELDING
PARAMETERS) ................................................................................17
11.1.2 MIG/MAG PARAMETERS SETTING (2ND LEVEL).........................18
11.1.3 MIG/MAG PARAMETERS SETTING (GAS MENU).........................18
12 JOBS MANAGEMENT..........................................................19
12.1 SAVING A JOB......................................................................19
12.2 LOADING A USER JOB OF FACTORY SET JOB ................19
12.3 DELETING A JOB .................................................................19
13 TORCH TRIGGER MODES ..................................................20
13.1 2T MIG/MAG WELDING........................................................20
13.2 4T MIG/MAG WELDING........................................................20
13.3 3 LEVEL MIG/MAG WELDING..............................................20
14 TECHNICAL DATA...............................................................21
15 SPARE PARTS .....................................................................22
15.1 321 HDP ................................................................................22
15.2 WIRE FEEDER MOTOR .......................................................24
15.3 WIRE FEEDER ROLLS......................................................... 25
16 ELECTRICAL DIAGRAM ..................................................... 26
16.1 321 HDP................................................................................26
16.2 REMOTE CONTROLLER .....................................................27
16.2.1 RC03: ELECTRICAL DIAGRAM ...................................................... 27
16.2.2 RC04: ELECTRICAL DIAGRAM ...................................................... 27
16.2.3 RC05: ELECTRICAL DIAGRAM ...................................................... 28
16.2.4 RC06: ELECTRICAL DIAGRAM ...................................................... 28
16.3 PUSH-PULL (OPTIONAL).....................................................28

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1INTRODUCTION
IMPORTANT!
This handbook must be consigned to the user prior to
installation and commissioning of the unit.
Read the "General prescriptions for use" handbook supplied
separately from this handbook before installing and
commissioning the unit.
The meaning of the symbols in this manual and the associated
precautionary information are given in the "General
prescriptions for use”.
If the "General prescriptions for use" are not present, it is
mandatory to request a replacement copy from the
manufacturer or from your dealer.
Retain these documents for future consultation.
KEY
This symbol identifies an action that occurs automatically as
a result of a previous action.
This symbol identifies additional information or a reference to
a different section of the manual containing the associated
information.
§
This symbol identifies a reference to a chapter of the manual.
This symbol accompanies important information concerning
the execution of the relevant operations.
321 HDP is a synergic three-phase inverter suitable for workshops,
car body repairs, light to medium carpentry and welding on
positioners.
Accessories that can be connected to the unit:
−liquid cooler for torches.
The available procedures in the MIG/MAG modality are:
PROCEDURE
TWO STEP (2T)
FOUR STEP (4T)
THREE LEVEL (3T)
2FRONT PANEL
1 2 3 4 5 6
7 8
1: Welding power source ON/OFF switch.
2: Mains protection ON LED.
This LED illuminates if an incorrect operating condition occurs:
−absence of a phase in the power supply line.
3: Earth welding socket.
4: Remote controller connector.
5: Provision for connection of the push pull torch (purchasing and
installing the relative kit).
6: MIG/MAG torch connector.
4: Connector for coolant hose.
Torch Power source
5: Connector for coolant hose.
Power source Torch

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3REAR PANEL
4 5 6 3
1 2
1: Connector for coolant hose.
Cooler Power source
2: Connector for coolant hose.
Power source Cooler
3: Gas rear connector. This is for the connection of the gas pipe
coming from the bundle of cables.
4: Cooler power feeding connector.
Voltage
230 V~
Current output
0.8 A
IP protection rating
IP20 (cap open)
IP66 (cap closed)
WARNING!
High voltage!
If the socket is not connected to any devices always close the cap:
presence of hazardous voltage levels!
5: Power supply transformer fuse.
Type
Delayed acting (T)
Amperage
2 A
Voltage
250 V
6: Power cable.
Total length
(including internal part)
4.5 m
Number and cross section of wires
4 x 2.5 mm2
Power plug type
Not supplied
4INSTALLATION
WARNING!
Lifting and positioning
Read the warnings highlighted by the following symbols in the
“General prescriptions for use”.
4.1 UNIT ASSEMBLY
1. Fit the front swivel wheels with the supplied screws.
2. Screw the fixed rear wheels to the studs in the base of the unit
and secure them with the supplied nuts.
3. Mount the cooler in the relevant location.
4. Screw the cooler fixing bracket to the welding power source
chassis using the supplied screws.
5. Screw the base of the cooler to the unit base using the supplied
screws.
6. Connect the plug of the cooler power cable to the cooler power
socket on the rear panel of the welding power source.

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4.2 CONNECTIONS TO THE ELECTRICAL MAINS
NETWORK
The characteristics of the mains power supply to which the equipment
shall be connected are given in the section entitled “technical data” on
page 21.
The machine can be connected to motorgenerators provided their
voltage is stabilised.
Connect/disconnect the various devices with the machine switched
off.
4.3 WIRE SPOOL POSITIONING
1. Open the unit side door to gain access to the spool compartment.
2. Unscrew the cap of the spool holder.
3. If necessary, fit an adapter for the wire spool.
4. Fit the spool in the spool holder, ensuring it is located correctly.
5. Adjust the spool holder braking system by tightening/loosening the
screw in such a way that the wire feed force is not excessive and
when the spool stops rotating no excess wire is released.
6. Refit the plug.
4.4 POSITIONING THE WIRE IN THE WIRE FEEDER
1. Lower the wire feeder pressure devices.
2. Raise the wire feeder pressure arms.
3. Remove the protective cover.
4. Check that the feed rolls are suitable for the wire gauge.
§ 15.3 WIRE FEEDER ROLLS
−The diameter of the roll groovemust be compatible with the
diameter of the welding wire.
−The roll must be of suitable shape in relation to the composition of
the wire material.

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−The groove must feature a "U" profile for soft materials
(Aluminium and its alloys, CuSi3).
−The groove must be "V" shaped for harder materials (SG2-SG3,
stainless steels).
−Rolls with a knurled groove profile are available for flux-cored
wire.
5. Feed the wire between the wire feeder rolls and insert it into the
MIG/MAG TORCH connector plug.
6. Make sure the wire is located correctly in the roll grooves.
7. Close the wire feeder pressure arms.
8. Adjust the pressure system so that the arms press the wire with a
force that does not deform it while also ensuring constant feed
rate without slipping.
9. Refit the protective cover.
10. Set the welding power source ON/OFF switch to “I” (unit
powered).
11. Feed the wire through the torch until it protrudes from the tip,
pressing button on the unit front panel.
4.5 CONNECTIONS TO SOCKETS
1. Set the welding power source ON/OFF switch to “O” (unit de-
energized).
2. Plug the power cable plug into a mains socket outlet.
3. Connect the gas hose from the welding gas cylinder to the rear
gas socket.
4. Open the cylinder gas valve.
5. Connect the power supply cable of the cooling unit to the auxiliary
power socket on the power source.
6. Attach the coolant hoses to the relevant connectors on the cooler
and on the power source rear panel.
7. Connect the MIG/MAG torch plug to the EURO TORCH welding
socket.
8. Attach the coolant hoses of the MIG/MAG torch to the relevant
connectors on the power source front panel.
9. Connect the plug of the ground clamp to the welding socket on the
basis of the polarity required.
10. Connect the earth clamp to the workpiece being processed.
11. Set the welding power source ON/OFF switch to “I” (unit
powered).
12. Feed the wire through the torch until it protrudes from the tip,
pressing button on the unit front panel.
13. Select the torch trigger procedure on the user interface.
14. Press the torch trigger with the torch well clear of any metal parts.
This serves to open the gas solenoid valve without striking the
welding arc.
15. Use the flow control valve to adjust the flow of gas as required
while the gas is flowing out.
16. Set the required welding parameter values on the user interface.
17. On connecting and enabling a remote controller [RC] certain
settings can be modified from said controller without having to
take action on the user interface of the welding power source.
The system is ready to start welding.
MIG/MAG installation

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5USER INTERFACE
CODE
SYMBOL
DESCRIPTION
L1
When this LED illuminates the following parameter can be set: WIRE FEED RATE
The value appears on the following display: D1
L2
When this LED illuminates the following parameter can be set: WELDING CURRENT
The value appears on the following display: D1
L3
This LED illuminates to show an anomaly in the operating conditions.
An alarm message appears on the following display: D1-D2
§ 9 ALARMS MANAGEMENT
L4
When this LED illuminates the following parameter can be set: WELDING THICKNESS
(Reference is made to "T" fillet welds on identical thicknesses. The relative value is purely guideline).
The value appears on the following display: D1
L5
When this LED illuminates the following parameter can be set: WELDING PROGRAM
The value appears on the following display: D1
L6
Illuminates to show the last voltage and current values measured during welding.
The LED switches off when a new welding procedure is started, or when any of the welding settings is modified.
The value appears on the following displays: D1-D2
L7
Illuminates to show a value in the following unit of measurement: METRES PER MINUTE
Illuminates together with the following LED:
The value appears on the following display: D1
L8
Illuminates to show a value in the following unit of measurement: AMPERES
The value appears on the following display: D1
L9
Illuminates to show a value in the following unit of measurement: MILLIMETRES
Illuminates together with the following LED:
The value appears on the following display: D1
L10
This LED illuminates to confirm the presence of power on the output sockets.
L11
Illuminates to show that the cooling unit pressure switch does not detect any pressure.
L12
Illuminates to show a value in the following unit of measurement: SECONDS
The value appears on the following display: D2
L13
Illuminates to show a value in the following unit of measurement: VOLTS
The value appears on the following display: D2
L14
Illuminates to show a value in the following unit of measurement: PERCENTAGE
The value appears on the following display: D2
L15
Illumination shows that the following function has been activated: 2 times procedure
§ 13.1 2T MIG/MAG WELDING

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L16
Illumination shows that the following function has been activated: 4 times procedure
§ 13.2 4T MIG/MAG WELDING
L17
Illumination shows that the following function has been activated: 3 levels procedure
§ 13.3 3 LEVEL MIG/MAG WELDING
D1
During illumination of the following LEDs: / / /
The display shows the value of the selected parameter.
Welding: The display shows the effective amperes value during welding.
HOLD function (at welding end): The display shows the latest measured current value.
Menu function: The display shows the acronym of the parameter or function to be adjusted.
Programs setting: The display shows the message P “program no.”.
D2
Data setting: The display shows the value, in Volts, of the selected welding voltage.
Welding: The display shows the effective voltage value during welding.
HOLD function (at welding end): The display shows the latest measured voltage value.
Menu function: The display shows the value of the parameter or function to be adjusted.
Programs setting: The display shows the acronym of the material to be welded on the basis of the selected synergic curve.
S1
This button activates wire feed to insert it through the MIG/MAG torch.
The insertion speed is 2 m/min for 3 seconds, subsequently increasing to 10 m/min.
This function produces a slower feed rate and hence greater precision when inserting the wire when it enters the torch nozzle.
S2
This button opens the gas solenoid valve to fill the circuit and calibrate the pressure with the regulator on the gas cylinder.
S3
Press the button once to open the JOB upload menu.
Hold down the button for 3 seconds to gain access to the JOB save/delete menu.
§ 11 WELDING SETTINGS
S4
Manual MIG/MAG mode: The button cycles through the following LEDs in sequence, selecting only one: /
Synergic MIG/MAG mode: The button cycles through the following LEDs in sequence, selecting only one: / / /
Data setting: Hold down the button for 3 seconds to gain access to the second level menu.
§ 11.1.2 MIG/MAG PARAMETERS SETTING (2ND LEVEL)
S5
This button selects the torch trigger procedure.
E1
Data setting: The encoder adjusts the main welding (and synergy) parameter, shown on the following display: D1
Menu function: The encoder selects the function or parameter to be adjusted.
E2
Manual MIG/MAG mode: The encoder adjusts the welding voltage, and the relative value is shown, in volts, on the following display: D2
Synergic MIG/MAG mode: The encoder is used to correct the factory-set value of the selected synergic curve, the value of which is shown on
the following display: D2
POT1
Manual MIG/MAG mode: The potentiometer sets the inductance value.
Synergic MIG/MAG mode: The potentiometer sets the inductance value from the minimum to the maximum permissible value in accordance
with the selected synergic curve.
K1
Control release: When the key is in this position all the functions of the machine can be changed.
K2
Control lock: When the key is in this position, some functions of the panel are disabled.
The functions disabled depend on the blocking status selected.
§ 8.1 LOCKING PROCEDURE