REHM BOOSTER2 130 Supplement

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REHM WELDING TECHNOLOGY
BOOSTER2 130 - 150
SHORT GUIDE

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Name Electrodes welding unit
Type
BOOSTER2 130 Order No.: 150 3113
BOOSTER2 140 Order No.: 150 3114
BOOSTER2 150 Order No.: 150 3115
Manufacturer:
REHM GmbH u. Co. KG Schweißtechnik
Ottostr. 2
D-73066 Uhingen
Telephone: [phone]
Telefax: +49 (0)7161/3007-20
e-mail: [email protected]
Internet: http://www.rehm-online.de
Doc.-No.: 730 2441
Date of issue 03.07.2018
The content of this description is the sole property REHM GmbH u. Co. KG Schweißtechnik
The copying and distribution of this document, 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.
 Productidentication

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Dear Customer,
You have purchased a REHM welding inverter and thereby a renowned German brand name.
We thank you for the condence you have placed in our quality products.
The BOOSTER2 is a professional welding unit for the electrode welding of all commercially
available electrodes (electrode welding corresponds to manual arc welding according to
DIN1910). The digital processor control and the highly dynamic power section with its cycle
frequency of 100 kHz offer you the best welding properties. All you have to do is select the right
welding current. The low weight of only 2.3kg and the extremely compact size enable easy
handling. With its robust plastic housing, the BOOSTER2 is the ideal companion in the workshop
and also for tough outdoor use on the construction site.
Technical data:
- Max. Output current 130,140,150A at a duty cycle of 35,25,20% (40°C)
- Output current 100 A at a duty cycle of 100% (40°C)
- High open circuit voltage of 91V
- Hot start functionality
- Continuous electronic mains voltage monitoring range 150V...250Vac
- Anti-stick function - no burn-out of the electrode if it accidently sticks
- Protection type IP23
The BOOSTER2 can be used universally for all welding tasks on stainless steels, high-alloyed
and low-alloyed steels as well as on non-ferrous metals and therefore makes an excellent
all-round partner.
This operating and function manual must be carefully and completely studied before starting the
unit for the rst time.
The information given in this manual is believed to be correct, however REHM does not accept
any liability for its use.
REHM GmbH & Co. KG Schweißtechnik reserves the right to adapt and change the design of
these welding units at any time.
If any points in this operating and functional manual are affected, then this is corrected in the
appendix to this manual under "Amendments and extensions".
1 Important user instructions

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The following safety instructions must be observed:
• Wear dry protective clothing, the eyes and face must be protected with a welding visor or
welding helmet (see VGB15).
• The unit is plugged into an earthed power outlet and is connected to power cables with a
properly grounded outlet.
• The unit switches off automatically in case of excessive temperature and automatically
switches back on after cooling down.
Caution: Put the electrode holder away in a safe place or hang it up so that the electrode
cannot strike and arc whilst in the thermal shutdown phase.
Alternatively: Remove the electrode
Caution: Non-observance may lead to a re hazard.
• The unit may only be maintained by trained specialists
If you have any problems, please contact REHM Customer Service at [phone].
When operating this unit, the accident prevention regulations for welding, cutting and related
processes (VGB 15) must be observed.
The main dangers are:
Fire and explosion
Hazardous substances (gases, vapours, smoke/dust)
Optical radiation
Electrical hazard
Handling errors
The units are designed for welding electrodes.
2 Safety instructions

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3.1 The Rehm control panel
The BOOSTER2 is operated via the REHM control panel shown in gure 3.1.
Figure: Front panel with controls and welding sockets
3 Functional description

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3.2 Electrode welding
The unit is suitable for welding all commercially available electrodes, whereby the maximum
current corresponds to the maximum output current of the unit. This current can be used to weld
standard electrodes up to 3.25 mm in diameter.
The polarity and current setting for the individual electrodes can be taken from the manufacturer's
specications of the electrodes. The electrode holder is plugged into the welding current socket
that has the polarity specied for the electrode (see sections 3.3 and 3.4).
All you need to do is select the correct welding current and polarity for the welding task at hand
and the electrode selected for the task. Booster2 does the rest for you. The following functions
automatically ensure good welding work:
3.2.1 Hot start
BOOSTER2 delivers a higher current than the set welding current for approx. ½ second when
starting to weld. The increase is limited by the maximum output current. This ensures good
ignition characteristics and a fast stable arc.
3.2.2 Arc force
BOOSTER2 monitors the welding current and welding voltage during welding. If BOOSTER2
detects that a droplet transition occurs in short circuit, it supplies a higher current than the set
welding current for a short time to quickly release the short circuit. This prevents the BOOSTER2
from dropping out or the electrode sticking during welding.
3.2.3 Anti stick function
If a permanent short-circuit is present during electrode welding, then after 1.0 s the anti-stick
function initiates which limits the output voltage and in turn the current to 5 volts. This prevents the
electrode from burning-out and the permanent short circuit can be easily released by lifting the
electrode.
The control panel is divided into the following zones:
Control lamps for operation and excess temperature
Rotary knob for preselecting the welding current
Label for identifying the BOOSTER2 version B130 / B140 / B150
The symbols on the control panel have the following meanings:
LED lamps Indicator function
Lights up Open-circuit voltage at the torch
or electrode holder.
Flashes quickly The unit is in fault mode
Switch the unit off and back on again
Flashes once per second The unit is in test mode
Switch the unit off and back on again
Temperature indicator.
The LED (yellow) lights up when the maximum permissible unit temperature is
exceeded. The output current is switched off for as long as this LED is lit. Once
the unit has cooled the LED goes out and welding can commence automatically.
Use CAUTION with the electrode!
B130

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3.3 The weld sockets
Connection for ground and electrode cables of Ø16 mm2 and 9mm plug. Maximum current 200A.
Figure: Welding cable connecting sockets
Connections: Rutile electrodes
"-" Electrode holder
"+" Ground cable
Basic electrodes
"-" Ground cable
"+" Electrode holder
Accessories: Ground cable Rehm item number 7810107
Electrode cable Rehm item number 7810205
4. Mains connection
The welding unite is equipped with a safety plug.
The unit is operated on fuses or circuit breakers with a rated current of at least 16A. The unit can
be operated with welding power that can trigger a 16A fuse via the thermal melt integral.
The operating status ON is indicated by the power switch on the rear of the unit. BOOSTER2
permanently monitors the mains voltage. If values that are too high (above 255V~) or too low
(below 180V~) are detected during operation, the unit switches off automatically and goes into a
protective function.
Once the mains voltage is correct, working is continued by switching the unit off and on again.

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5 Installation
When installing the unite, ensure that the ventilation slots are not covered and that the environment
complies with protection class IP23.
When working in dusty environments, the cooling channel of the unit may become dirty and limit the
unit capacity. The air duct is cleaned in a service
workshop by blowing out.
6 Restrictions on use
The unit can be used in all environmental conditions that comply with protection class IP23 or lower.
For welding in certain environments (e.g. stables), special demands are placed on the welding unit
protection class. The possibility of using the unit in such an environment must be checked in detail.
The unit is not intended for multi-shift operation.
7 Maintenance
The unit is maintenance-free, but the condition of the electrical connection cables must be checked
regularly.
8 Electro-magneticelds(EMF)
Electric current passing through any conductor created local electric and magnetic elds (EMF).
Welding current generates an electromagnetic eld around the welding current circuit and the welding
equipment.
Electromagnetic elds can interfere with some medical implants such as cardiac pacemakers.
Measures must be taken to protect persons with medical implants. This includes for example limiting
access for passers by or individual risk assessments for welders.
All welders should use the following measures to minimise their exposure to electromagnetic elds
generated by the welding circuit.
• Keep your head and body as far away as possible from the welding current circuit
• Do not place your body between the welding cables
• Both welding cables must run on the same side of the body
• Connect the return cable to the workpiece as close as possible to the site being welded.
• Never wind the welding cables around your body
• Never work in the vicinity of the welding current source, never sit on or lean against it
• Never perform welding when carrying the welding current source or the wire feed unit
• Power supply grid lter
• Shielding such as the use of shielded cables

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• Keep welding cables as short as possible
• Grounding the workpiece
• Potential equalisation
• Lay welding cables together and secure with adhesive tape if necessary
The user is responsible for malfunctions in the surrounding environment of the welding unit. For
more information and recommendations, see, inter alia, DIN EN60974-10: 2008-09, Annex A.
9 Generator suitability
The unit can be operated with a 1-phase generator, the full welding current can be drawn from
5 kVA generator power. Generators with lower output switch off if the welding current settings are
too high.
The 1-phase Booster cannot be operated on three-phase generators due to the excessive
asymmetric load (exception: special generators for re brigade use).
If these units use a Schuko socket the booster can be used up to the power limit of this socket
(usually 10 or 16A). If the welding current is set too high a circuit breaker on the generator will
drop out.
10 Disposal
Only for EU countries.
Do not dispose of electric appliances in domestic waste!
In accordance with the European Directive 2002/96/EC concerning old electrical
and electronic devices and its transposition into national law, used electrical
appliances must be collected separately and recycled in an environmentally friendly
manner.

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EC declaration of conformity
For the following named products
BOOSTER2 130/140/150
it is hereby conrmed that they comply with the essential protection requirements which are laid down
in the Directive 2004/108/EU (EMC Directive) of the council on the approximation of the laws of the
Member States relating to electromagnetic compatibility and in the Directive 2006/95/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 60 974-1: 2013-06
Arc welding equipment - Part 1: Welding power source
EN 60 974-3: 2014-09
Arc welding equipment - Part 3: Arc striking and stabilizing devices
EN 60974-10: 2008-09
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 2006/95/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, 03.07.2018
submitted by R. Stumpp
Managing Director

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Please contact your local distributor:
Status 07/18 · Item no. 730 2441
REHM Service Hotline: Tel.: [phone] REHM online: www.rehm-online.de
Fax.: [phone]
REHM GmbH u. Co. KG Schweißtechnik
Ottostraße 2 ▪D-73066 Uhingen
Telephone: [phone]
Telefax: [phone]
E-Mail: [e-mail]
Internet: http://www.rehm-online.de
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Thanks to this central organisation and our forward-thinking
policies, new discoveries can be rapidly incorporated into
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customers form the basis for our innovative product
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Customer proximity and competence are the principles
which take highest priority in our consultation, training and
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