Most PONTE 201 PRO MOST User manual
User Manual for Inverter
Rectier
PONTE 201 PRO MOST
User Manual
Version 1.2 of 7.04.2021EN
Catalogue no: 53 00 030685
Before starting work every person using or responsible for maintenance work on this
device should familiarize with the entire content of these operating manual. This will
optimize the use of device potential.
Attention! Prior commencing work please familiarize yourself with the user manual.
Attention! A copy of this User Manual should be stored near the device and available
for operator at all times.
User Manual
Version 1.2 of 7.04.2021EN
PONTE 201 PRO MOST -2-
Thank you for buying the Inverter Recti¿er PONTE 201 PRO MOST. We do believe that this
product will meet your requirements. In order to ensure the correct use, all the safety and
operating instructions should be read before operating this device.
The PONTE 201 PRO is not subject to the Ecodesign Directive 2009/125/EU – see Regulation
2019/1794 (EU) art. 1 pt 3b and art. 2 pts 13A and C.
1. Health and Safety Manual
ATTENTION: The device can not be used for the purpose of pipe defrosting!
Information included on icons located on the device.
Use and maintenance of welding equipment may be dangerous. The user must
observe health and safety rules and regulations. Welding and cutting machines
may be used only by quali¿ed personnel. The national regulations for working with
this device and accident prevention should be kept up to date.
All ammable or combustible materials must be removed from the working area.
Welding inside tanks previously used as ammable liquids storage is forbidden.
Place all combustible materials away from welding spatter.
Do not expose the device to rain or water vapour and do not spray water over it.
Do not weld without proper eye protection. Pay attention to providing safety for
bystanders against welding radiation.
Use ventilation and ¿lters in order to remove welding fumes from the work site.
Use individual ¿lters if the ¿ltering/ventilation system does not operate properly or
is not available.
Stop your work immediately after ¿nding damage to the power cords. Do not touch
the damaged cords. Prior to repair or maintenance disconnect the device from
power source. Never use the device with damaged power cords.
Keep a ¿re extinguisher close to the welding location. After ¿nishing welding ope-
rations always
check the work station against ¿re hazards.
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PONTE 201 PRO MOST -3-
Electromagnetic interference.
The device may inuence other devices sensitive to electromagnetic interference
(robots, computers, etc.)
Make sure that the devices within the welding work station are resistant to inter-
ference.
The device is compliant with the currently applicable standards. In accordance
with EN IEC 60974-10 is classsi¿ed as class A and is intended for use in workshop
and industrial conditions. The device application nearby to residential buildings,
especially the power supply using a home domestic network, may interfere with
the operation of other electrical or telecom devices.
In order to minimize interference it is recommended to use possibly shortest we-
lding cables arranged in parallel. Always work in a distance at least 100m from
other sensitive devices. Always make sure that the installation is grounded.
In case of interference with other devices, shield the cables or use appropriate
¿lters.
INTRODUCTION
Commissioning and normal operation are possible only after carefully reading the following ma-
nual. Manual metal arc (MMA) welding requires compliance with the requirements for electric
arc welding and ¿re regulations. Device operator should be equipped with appropriate personal
protective equipment. It is necessary to use a set of compatible protective equipment with the
provisions of the Regulation of the European Parliament 2016/425 (PPE). Personal protective
equipment includes: welding mask, welding gloves, protective apron, leather
shoes, non-ammable welding clothing.
Despite the high technical standard of the device, the personnel should demonstrate consi-
derable discipline in terms of health and safety requirements that protect against harmful and
health hazardous factors resulting from welding technology.
OPERATING CONDITIONS
In order to ensure adequate service life and trouble-free operation:
- do not place or use this device on an inclined surface (of more than 15º),
- do not use the device for pipe defrosting,
- the device needs to be located in a place with free air circulation (with no restrictions of the air
ow to and from the fan). When connected to electrical network the device must not be
covered (for example, with paper or cloth),
- minimize the amount of dirt and dust that can get into the device,
- device has an IP21S protection rating and may not be exposed to direct atmospheric
precipitation,
- do not use the device for welding the tanks previously used for storing ammable substances.
GASES AND FUMES
During MMA welding harmful gases and fumes containing ozone and hydrogen as well as oxi-
des or metal particles are produced. Therefore, the welding work station should be ¿tted with
very good ventilation (dust and smoke extraction) or should be placed in airy location. Metal
surfaces intended for welding should be free from chemical contamination, especially degre-
asers (solvents) that decompose during welding process and produce toxic gases. Welding
of galvanized or cadmium-coated or chrome-plated parts is only permitted with the use of a
mechanical ventilation and ¿ltering device and on condition that the adequate supply of fresh
air is provided to the welding station.
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PONTE 201 PRO MOST -4-
RADIATION
Ultraviolet radiation emitted during welding is harmful to eyesight and skin. Therefore a welding
mask with protective ¿lters is required. Welding work station should meet certain requirements,
including:
• adequate lighting system,
• ¿xed or movable protection screens, governing bystanders against radiation e-•ects
(depending on requirements),
• placed in a room with appropriate wall colour (absorption of UV radiation)
FIRE PROTECTION
Welding work station should be located at a safe distance from ammable materials placed
especially on the oor or walls. All ammable materials need ¿re protection against hot metal
drops. It is recommended to ¿t the work station with ¿re blankets and ¿re extinguishers.
PROTECTION AGAINST ELECTRIC SHOCK
It is unacceptable to connect the device to an improper installation or to an installation
with unveri¿ed zeroing e-ciency. Removal of external shields while the device is connected to
the electric network, as well as the use of the device with shields removed is prohibited. It is not
allowed to work on a suspended device (e.g. using a crane or a gantry). Maintenance and
repair works should be carried out by authorized personnel in compliance with the applicable
safety conditions.
2. Maintenance
ATTENTION: In order to carry out any repair or maintenance activity, it is recommended to
contact your nearest technical support of RYWAL-RHC (a list of authorized service shops is
available on the last page of the manual).
In the event of noticing any damage, the welder should stop working, disconnect the device
from power supply and report it to direct supervisor or appropriate service - RYWAL-RHC tech -
nical support.
General maintenance (daily)
- check the condition of cables and connections, replace if necessary,
- check condition of welding torch and connection with welding cable, replace if necessary,
- check condition and operation of the cooling fan; keep the cooling air inlet and outlet openings
clean,
- keep the device clean.
Periodic maintenance (every 3 months at least)
Periodic maintenance frequency can be increased depending on working conditions and the
intensity of use. Maintenance:
- using a stream of dry air (at low pressure) remove the dust from the outer parts of the casing
and from inside of the welding device,
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PONTE 201 PRO MOST -5-
- check and tighten all the screws,
- check the state of all electrical contacts and repair if necessary.
ATTENTION: Power supply must be disconnected from the device before any maintenance
and service work. After each repair, perform a proper check to ensure safe use.
Mandatory device checks
According to the Labour Code provisions: „All responsibility for the safe use of machinery and
equipment shall be borne by the owner.”
This results in the obligation to perform periodic and post-repair checks and inspections of
equipment.
Periodic tests are carried out at least once a year (legal basis EN ISO 17662 clause 4.2), and
post-repair tests after each repair that restored welding functionality (legal basis: EN 60974-4
clause 4.6).
All above services are performed by the technical support of RYWAL-RHC.
3. Technical description and operating conditions
PONTE 201 PRO are cutting edge inverter recti¿er for MMA coated electrode welding. The de-
vice can use for welding the majority of electrodes with a rutile, alkaline or acid coating, except
for cellulose electrodes that require a high idling voltage U0.
The device is powered from a single-phase 230 V.
The control panel on the front of the device has a digital welding current display.and a knob
to set it. The edges of the housing are secured with rubber shock absorbers. The device has
large 35/50 Dinse sockets.
The device is protected against overheating by a thermal sensor and coolong fan. Made in
accordance with EN 60974-1
standard. Range of air temperatures:
- operating temperature from -10oC to +40oC,
- transport and storage temperature from -25oC to + 55oC.
Relative air humidity up to 50% at +40oC and up to 90% at +20 oC.
According to the Ecodesign Directive 2009/125/EU and Regulation 2019/1794 (EU)
PONTE 201 PRO is classi¿ed as arc welding equipment with a limited load and is not intended
for industrial or professional use.
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PONTE 201 PRO MOST -6-
Paramete Unit Value
Electrical power supply V/Hz 1x230/50-60
Welding current range A 10-200
Open circuit (MMA) U 0V 63
Overload protection A16 (fuse delayed)
Current Ie-• A 14
Current I1max A 44
Work cycle MMA A/% 200/10 82/60
63/100
Maximum power consumption kW 6,6
Insulation class F
Protection class IP 21S
Noise emmision dB(A) <70
EMC noise level according to
EN IEC 60974-10 Class A
Dimensions mm 375x140x290
Weight kg 5,9
Catalogue no. 53 00 030685
4. Technical data
Table 1: Technical data PONTE 201 PRO MOST.
The device is delivered in a plastic case containing user manual booklet and an earth cable
with a clamp and a cable with electrode holder. Both cables are 3 meters long.
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PONTE 201 PRO MOST -7-
5. Device construction
Figure 1: PONTE 201 PRO MOST construction
1. Power indicator LED lights up when the device is ON (by switch no. 8).
2. Overheat indicator LED is on if the device is overheated due to exceeding the welding work
cycle. Wait for the fan to cool down the device.
3. Socket (+) to connect the electrode cable (see polarity recommendations on the electrode
pack).
4. Socket (-) To connect earth cable with a clamp (see polarity recommendations on the
electrode pack).
5. Current control knob for setting the welding current in amperes
6. Handle
7. Welding current display.
8. Main power switch for switching ON/OFF the device.
9. Power connection: power cable with a plug.
10. Fan cover.
8
9
10
6
5
2
4
1
7
3
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PONTE 201 PRO MOST -8-
6. MMA coated electrode welding
1. Connect the electrode lead cable and ground cable to the 3 (+) and 4 (-) sockets
following the guidance in user manual for each electrode type (Figure 1)
2. Turn on the device 8 (switch to ON position)
3. Welding current is set using the knob 5depending on the diameter of the electrode.
- see electrode manufacturer’s recommendations.
4. During welding, the display shows the measured values of the welding current.
5. The measured value (HOLD) stays visible on the display for a few seconds after welding.
Earth cable with a clamp
Welded material
Electrode lead cable with electrode holder
Figure 2: Ignition of the welding arc during MMA welding
After connecting to the mains and starting the device with the ON / OFF switch, set the proper
welding current for the given diameter of the electrode with the knob (see instructions on the
electrode pack). The approximate welding current is assumed to be 30-40 [A] per 1 mm
thickness of the welded workpiece.
The electric arc is initiated by rubbing the end of the electrode with the base material
(connected with the device by earth cable), and after the arc occurs, it is necessary to quickly
move the tip to a certain distance. (see Figure 2) If the end of the electrode is removed too
quickly, the arc will be torn o-• and alternatively, moving too slow can result in creating short
circuit and sticking the end of the electrode to the material.
Additional functions HOTStart (support of arc ignition) and ArcForce (adaptation of the arc by
pipe welding) are active. The values of settings for HotStart and ArcForce are not adjustable.
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7. Spare parts and device construction
Figure 3: PONTE 201 PRO MOST spare part list
No. Part no. Part name Qty.
1 10062158 rear panel 1
2 10056467 power switch 1
3 10004898 cable clip 1
4 10007333 fan guard 1
5 10056858 fan 1
6 10060830 windshield 1
7 10069138 column 2
8 10050392 thermal resistance 1
9 10046932 left rubber feet 2
10 10065123 bracket of EMC 1
11 10060825 machine base 1
12 / Al connection 1
13 10046712 display meter 1
14 10037028 angle support 1
15 10046933 right rubber feet 2
16 / copper connection 1
17 10021855 quick socket 2
18 / front panel sticker 1
19 10040930+10059709 knob& potentiometer 1+1
20 10059607 cover 1
21 10047106 front plastic part 1
22 10050074 handle 1
23 10047109 rear plastic part 1
24 10060827 beam 1
25 / main board 1
26 10050419 heat sink 1
27 10057048 heat sink 2
28 10060824 front panel 1
29 10069558 EMC board 1
ARC200 Z244 EV
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PONTE 201 PRO MOST -10-
Pos. Part code Name Quantity
1 10062158 Rear panel 1
2 10056467 ON/OFF switch 1
310021912 Cable ¿tting 1
4 10007333 Fan cover panel 1
5 10056858 Fan 1
6 10060830 Air inlet cover 1
710069138 Column 2
810057939 Thermal resistor 1
9 10046932 Left rubber foot 2
10 10065123 Bridge EMC 1
11 10060825 Bottom frame 1
12 10070089 Aluminium rail 1
13 10046712 Display 1
14 10037028 Bracket 2
15 10046933 Right rubber foot 2
16 10070088 Copper buzzbar 1
17 10021855 Dinse socket 2
18 10070136 Front label Ponte 201 1
19 10047127 + 10059709 Knob + potentiometer 1
20 10070084 Upper cover 1+1
21 10047106 Front plastic cover 1
22 10050074 Handle 1
23 10047109 Rear plastic cover 1
24 10060827 Beam 1
25 10070233 PCB mainboard 2
26 10060850 Radiator/heat sink 1
27 10054622 Radiator/heat sink 2
28 10070113 Front panel 2
29 10069815 EMC board 1
Table 2: PONTE 201 PRO MOST spare part list
8. Troubleshooting during MMA welding
ATTENTION:
The device can be repaired only by authorized personnel!
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Problem Potential cause
Excessive splatter 1. Arc too long
2. Too high welding current
Crater 1. Too quick detachment of the electrode from workpiece
Inclusions - slagging 1. Low material purity or densely placed welds
2. Incorrect electrode leading
Lack penetration, no sticking
1. Too high welding speed
2. To low welding current
3. Too small bevel angle
4. Incorrect edge cleaning
Electrode sticking to the
workpiece being welded 1. Arc too short
2. To low welding current
Bobbles in weld 1. Moistened electrode coating
2. Arc too long
Cracks in weld 1. Too high welding current
2. Welded workpiece dirty
3. Hydrogen in weld (from electrode coating)
LED 2 switches on to signal
overheating
1. Exceeded device operation cycle - see the data plate on the
equipment. Do not turn the device o-• until the fan cools down and the
LED 2 turns o-•.
2. Internal damage - contact RYWAL-RHC service
9. Electrical scheme
Figure 4: PONTE 201 PRO MOST wiring diagram
Table 3: Faults during MMA welding.
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10. EU Declaration Of Conformity
1. Product: Inverter Recti¿er PONTE 201 PRO MOST
2. Name and address of the producer:
RYWAL-RHC sp. z o.o. Warszawa
Chełm*y1ska 180 04-464 Warszawa,
3. This declaration of conformity is issued under the sole responsibility of the
manufacturer.
4. Object of the declaration: Inverter Recti¿er PONTE 201 PRO MOST
5. The subject matter of this declaration mentioned above is in conformity with the
relevant requirements of EU harmonization legislation:
- The Low Voltage Directive LVD 2014/35/EC,
- The Electromagnetic Compatibility EMC Directive 2014/30/EU,
- The directive on the restriction of the use of certain hazardous substances used in electrical
and electronic equipment RoHS 2011/65/EU
6. References to the relevant harmonized standards in relation to which conformity is
declared:
EN 60974-1:2012; EN 60974-10:2014 / +A1:2015.
7. Additional information: di-•erence between PONTE 201 and PONTE 201 PRO only in
accessories.
According to the Ecodesign Directive 2009/125/EU and Regulation 2019/1794 (EU)
PONTE 201 PRO is classi¿ed as arc welding equipment with a limited load and is not intended
for industrial or professional use.
Toruń, 23.04.2020
Signed on behalf of:
The devices are subject to constant changes and improvements.
We reserve the right to make changes.
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PONTE 201 PRO MOST -13-
11. Recycling
In accordance with Directive 2012/19 / EU WEEE II (WEEE - Waste Electrical and Electronic
Equipment), after decommissioning, the device must be recycled by a specialized company. Do
not dispose of worn-out welding equipment with domestic waste!
The End.
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