REHM BOOSTER.PRO 230 Supplement

GB
REHM SCHWEISSTECHNIK
BOOSTER.PRO 230
Electrode inverter
SHORT GUIDE

Short guide
BOOSTER.PRO 230 Order No.: 1513230
Manufacturer
REHM GmbH u. Co. KG Schweißtechnik
Ottostraße 2
D-73066 Uhingen
Telephone: [phone]
Telefax: +49 (0)7161/3007-20
E-Mail: [email protected]
Internet: http://www.rehm-online.de
Doc. No.: 7302157
Date of issue: 17/08/2020
©REHM GmbH u Co. KG, Uhingen, Germany 2020
The content of this description is the property of Rehm GmbH u. Co. KG
The copying and distribution of this document, its use and communication of its contents are strictly
prohibited unless expressly authorized.
Offenders are liable to damages. All rights reserved in the event of patent, utility model or design
patent.
The manufacture based on these documents is not allowed.
Subject to change.

2
Contents
1General safety instructions............................................................................ 3
2System description......................................................................................... 5
3Operation description .................................................................................... 6
3.1 Overview oft he operating panel................................................................... 6
3.2 Operation in the main menu (Menu 1).......................................................... 7
3.3 Current curve (Menu 2)................................................................................ 8
3.4 Settings (Menu 3)....................................................................................... 10
4Circuit diagram ............................................................................................. 11
5Maintenance work......................................................................................... 12
5.1 Safety information ...................................................................................... 12
5.2 Maintenance table...................................................................................... 12

3
1 General safety instructions
The system was developed and designed by the generally accepted rules of
technology.
•Safety and warning instructions serve as occupational safety and accident
prevention. They must be observed.
•Beside the advice given in this short guide, the general safety and accident
prevention regulations (in Germany, among others UVV BGV A3, TRBS 2131
and BGR 500 Chapter 2.26 (previously VGB 15): "Welding, cutting and allied
processes" and particularly the conditions for arc welding and cutting
contained therein or the corresponding national regulations) must be
observed.
•Also observe the safety information signs on the factory floor of the operator.
•All safety instructions and warnings as well as the nameplate on / near the
system must be kept legible.
•Safety equipment must never be dismantled or put out of operation as this will
result in dangerous hazards and the intended use of the system is no longer
guaranteed. The dismantling of safety devices for equipping, repairing and
maintenance is described in detail. The safety devices must be refitted
immediately on completion of such work.
•Changes to the system or the mounting or incorporation of additional
equipment as well as the decommissioning of safety devices are not
permitted. Doing so will invalidate any warranty and liability claims.
• When using external aids and agents (for example, solvents for cleaning) the
user of the system is responsible for ensuring the safety of the unit.
•REHM welding systems are, except when this is expressly stated in writing by
REHM, only for sale to commercial / industrial users and are only intended to
be used by commercial / industrial users.
Technical data:
- Output current with electrode 140 A at a duty cycle of 100% (40°C)
- Output current with WIG 160 A at a duty cycle of 100% (40°C)
- Open circuit voltage from 85V
- Anti-stick function - no burn-out of the electrode if it accidentally sticks
- Protection type IP23

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BOOSTER.PRO welding systems are designed in accordance with EN 60974-1
Arc welding equipment - welding power sources for overvoltage category III and
pollution degree 3 and in accordance with EN 60974-10 Arc welding equipment
- electromagnetic compatibility (EMC) for Group 2 Class A and should be suita-
ble for use in all areas, except residential areas that are connected directly to a
public low-voltage supply system. It may possibly be difficult to ensure
electromagnetic compatibility in these areas due to both conducted and radiated
interference. For this purpose, the use of appropriate measures to meet the
requirements (filters for mains connection, shields such as shielded cables, the
shortest possible welding cables, earthing of the workpiece, potential
equalization) and assessment of the environment (such as computers,
controllers, radio and television broadcasters, adjacent people, for example
required in the use of cardiac pacemakers) are required. The responsibility for
any fault lies with the user. For more information and recommendations, see,
inter alia, DIN EN60974-10: 2008-09, Annex A.
Qualification of the operating personnel
REHM welding systems should be operated only by persons who are trained
and instructed in the use and maintenance of welding systems. Only qualified,
assigned and trained personnel may work on and with the system.
Personal protective equipment (PPE)
Personal protective equipment (PPE) is required when working with a welding
system:
•Welding protection filter, protection level 10-15
•Protective shield, screen or hood
•Protective gloves
•Leather apron
The employer is obligated to provide the required PPE to the operator
Environmental conditions
•Temperature range of ambient air:
- In operation: -10°C to +40°C (10°F to 104°F)
- During transport and storage: -20°C to +55°C (-4°F to 131°F)
•Relative humidity:
- to 50% at 40°C (104 °F)
- to 90% at 20°C (68 °F)
•Ambient air:
Free of unusual amounts of dust, acids, corrosive gases or substances, etc.,
unless they are produced during welding.
•Altitude above sea level: Up to 2000m (6500 ft).
Operation and storage of the system outside the specified range is considered
to be improper. The manufacturer is not liable for any resulting damage.
Requirements on the mains supply
The system may be connected and operated from a single phase 2-wire system
with earthed neutral conductor.

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2 System description
Front view
Rear view
1
2
3
4
5
6
7
8
9
No.
Symbol
Description
No.
Symbol
Description
1
Control panel - See
"Description of
controls"
6
Drawer –storage for
electrodes, gas
nozzles, etc.
2
Control panel push
and rotate knob
7
Main switch - On / Off
3
Current socket
"negative"
TIG:
TIG welding torch
Electrode:
Workpiece or
electrode holder
8
Power cable
4
Current socket
"positive"
TIG:
workpiece
Electrode:
Workpiece or
electrode holder
9
Cooling air outlet
5
Cooling air inlet

6
3 Operation description
3.1 Overview oft he operating panel
Fig 1: BOOSTER.PRO 230 control elements
Controls
Function
Fig. 1 Main screen
Main screen
Operation via rotary encoder
with push button.
Fig. 2 Push and rotary encoder
Rotary encoder with push-knob
Moves the pointer (cursor) on
the screen clockwise or
counter clockwise. Positions
reached are highlighted in
colour and are activated by
pressing the rotary encoder
knob. Hold the push-knob
down for two seconds to reach
the main screen.

7
3.2 Operation in the main menu (Menu 1)
Fig. 2: Main menu
Symbols
Description / function
Menu
1
The control cursor is positioned in the "Current setting"
field in the main menu as standard.
By pressing the rotary encoder the field will turn blue
and the welding current can be changed. This can also
be done in welding mode.
Pressing the rotary encoder once again confirms the
value, the field will turn white and the set value is
active.
The bar display shows in green the current range of the
Booster.Pro. Blue is the range that still has to be set.
Display of the welding function:
Procedure
Boost
Explanation
Rutile electrode
No
with fuse hold
Basic electrode
No
with fuse hold
Rutile electrode
Yes
Basic electrode
Yes
WIG LiftArc
---
The boost function must be switched ON or OFF in the
"Settings" menu under "Fuse Hold".
Menu 1Main screen
Menu 2Current curve
Menu 3Settings
It is possible to switch
between the menus by
turning and pressing.
VRD (Voltage Reduction Device) active.
The output voltage is limited to the very high-impedance
and consequently safe sensor voltage of 24V.
If there are active pulses, the average value is used to
set the current in the main menu.
An error has occurred, restart the device.
Contact the REHM customer service if the error
persists.

8
3.3 Current curve (Menu 2)
Fig. 3: Current curve
Symbols
Description / function
Menu
2
Current curve
Text display of the selected setting value
(parameter)
•Hotstart
•Hot-start-time
•Current I1 setpoint
•Current I2 setpoint
•Frequency for hyperpulses (frequency
pulses)
•Arc force
•Pulse
•Hyperpuls
Hot-start-current
Current increase for the Hot-start-time to ignite the
arc safely.
Hot-start-time
Time when the hot start current is active
Pulse current (I1)
is the current displayed on the main screen (Menu1)
which can also be adjusted from there.
When time pulses occur, current I1 is only present
for time t1 and then changes to current I2 for time t2.
The current mean value results from
I1 x t1 + I2 x t2 / (t1+t2)
e.g.: 120A x 0.3s + 80A x 0.3s / (0.3s+0.3s) = 100A
At hyperpulses (frequency pulses) the currents I1
and I2 change with the set frequency (f)
The percentage ratio to I1 displayed at I2 remains
unchanged when I1 is changed (I2 also changes)
provided that this is possible from the setting values.
Pulse-current time (t1)
Is displayed when time pulses are active.

9
Symbols
Description / function
Pulse-current (I2)
Only visible when time or hyperpulses (frequency
pulses) are set.
Pulse-current time (t2) or frequency (f)
The time t2 or the alternating frequency f is set
depending on whether time or hyperpulses
(frequency pulses) are set.
Arc Force
Power to keep the arc stable. The value is always
equal or higher than the current I1
Pulse On/Off
If the symbol is displayed in blue, the time pulse is
activated, in black it is deactivated.
If the pulse is inactive, the I2 display goes out.
HYPER.PULSE On/Off
If the symbol is displayed in blue, hyper pulsing is
activated, in black it is deactivated.
If the pulse is inactive, the I2 display goes out.
Anti Stick
This function prevents the electrode from sticking
and is always active.
Pulse display inactive
Display time/hyper pulses active
The symbol indicates that time pulses are active
The symbol indicates that hyperpulses
(frequency pulses) are active

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3.4 Settings (Menu 3)
Fig. 4: Settings menu
Symbols
Description / function
Menu
3
Settings
Process menu:
•Rutile electrode
•Basic electrode
•WIG LiftArc
Software version of the machine - Power
control
Software version of the operation
The fuse limitation can be activated or
deactivated here.
(Limits the maximum adjustable current)
Setting
Electrode
max. current
in A
TIG
max. current
in A
On
160
230
Off
180
230
Menu language selection
All of the unit settings can be reset to factory
settings here.

11
4 Circuit diagram

12
5 Maintenance work
5.1 Safety information
Warning!
Maintenance and repair work may only be performed by persons who have been trained
by REHM. Please contact your REHM dealer.
When replacing parts only use REHM original spare parts.
If maintenance or repair work is performed on this unit by persons who have not been
trained and authorised to carry out the work by REHM, then claims against REHM beco-
me void.
Before beginning cleaning work the unit must be switched off and disconnected from the
mains supply.
Before maintenance work the welding system must be switched off and disconnected
from the mains supply and secured against unintended reconnection.
Supply lines must be shut off and vented free of pressure.
The welding system and its components must be maintained in accordance with the
requirements of the operating and maintenance instructions.
Insufficient or improper maintenance or repair may result in operating faults. Periodic
maintenance of the system is therefore essential. No constructive change or additions may be
made to the system.
5.2 Maintenance table
The maintenance intervals are recommended by REHM for standard requirements (for example,
single shift operation, use in a clean and dry environment). The precise maintenance intervals
are specified by your safety officer.
Activity
Interval
Cleaning the inside of the unit
According to the
conditions of use
Functional test of the safety equipment by operat-
ing personnel
Daily
Visual system check, particularly the torch hoses /
elding current cable
Daily
Check the function of the residual current circuit
breaker
Daily
(in flying constructions)
otherwise monthly
Have the connecting lines and torch hoses
checked by qualified personnel; log the checks in
the logbook provided.
Perform checks more regularly depending
on the country-specific laws.
Every six months
Have the complete welding system checked by
qualified personnel; log the checks in the logbook
provided.
Perform checks more regularly depending on
the country-specific laws.
Annually

EG declaration of conformity
For the following named products
BOOSTER.PRO 230
it is hereby confirmed that they comply with the essential protection requirements which are laid
down in the Directive 2014/30/EU (EMC Directive) of the council on the approximation of the laws of
the Member States relating to electromagnetic compatibility and in the Directive 2014/35/EU relating
to electrical equipment designed for use within certain voltage limits.
The above products comply with the requirements of this directive and comply with the safety
requirements for arc welding units in accordance with the following product standards:
EN 60974-1: 2018-12
Arc welding equipment - Part 1: Welding current source
EN 60974-3: 2015-12
Arc welding equipment - Part 3: Arc striking and stabilizing devices
EN 60974-10: 2016-10
Arc welding equipment - Part 10: Electromagnetic compatibility (EMC) requirements
according to the EC. Directive 2006/42/EC article 1, paragraph 2 the above mentioned products fall
exclusively within the scope of the directive 2014/35/EC relating to electrical equipment designed for
use within certain voltage limits.
This declaration is given for the manufacturer:
REHM GmbH u. Co. KG Schweißtechnik
Ottostr. 2
73066 Uhingen
Uhingen, 17.08.2020
submitted by
R. Stumpp
Managing Director

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Stand 08/2020 | Artikel-Nr. 7302157