Weco Discovery 162T User manual

Cod. 006.0001.1940
15/02/2021 V.2.2
Discovery 162T
Instruction manual
ENG
Translation of original instructions

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ENGLISH

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INDEX
1 INTRODUCTION.......................................................................................................................................... 4
1.1 PRESENTATION.......................................................................................................................................... 5
2 INSTALLATION .......................................................................................................................................... 5
2.1 CONNECTIONS TO THE MAINS POWER SUPPLY .................................................................................. 5
2.2 FRONT PANEL............................................................................................................................................. 6
2.3 REAR PANEL............................................................................................................................................... 6
2.4 PREPARING FOR MMA WELDING............................................................................................................. 7
2.5 PREPARING FOR TIG WELDING ............................................................................................................... 8
3 USER INTERFACE ...................................................................................................................................... 9
4 UNIT POWER-UP ...................................................................................................................................... 10
5 RESET (LOAD FACTORY SETTINGS)..................................................................................................... 11
6 ALARM MANAGEMENT ........................................................................................................................... 12
7 MMA WELDING......................................................................................................................................... 12
7.1 MMA WELDING - FIRST LEVEL MENU .................................................................................................... 12
8 DC TIG WELDING ..................................................................................................................................... 14
8.1 DC TIG WELDING - FIRST LEVEL MENU ................................................................................................ 14
8.2 TIG DC WELDING - SECOND LEVEL MENU ........................................................................................... 19
8.3 TORCH TRIGGER PROCEDURE ............................................................................................................. 20
9 TECHNICAL DATA .................................................................................................................................... 25
10 WIRING DIAGRAM.................................................................................................................................... 27
10.1 TORCH CONNECTOR (front panel) .......................................................................................................... 28
11 SPARES..................................................................................................................................................... 29
11.1 TORCH CONNECTORS COMPLETE KIT................................................................................................. 30

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1 INTRODUCTION
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.
LEGEND
DANGER!
This pictogram warns of danger of death or serious injury.
WARNING!
This pictogram warns of a risk of injury or damage to property.
CAUTION!
This pictogram warns of a potentially hazardous situation.
INFORMATION!
This pictogram gives important information concerning the execution of the relevant operations.
This symbol identies an action that occurs automatically as a result of a previous action.
This symbol identies additional information or a reference to a different section of the manual
containing the associated information.
§ This symbol identies a reference to a chapter of the manual.
*1 The symbol refers to the associated numbered note.
NOTES
The gures in this manual are purely guideline and the images may contain differences with respect to
the actual equipment to which they refer.

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1.1 PRESENTATION
Discovery 162T is an inverter DC TIG/MMA portable welding power source.
The sturdiness of the components of this unit makes it a reliable working companion for workshop and
outdoor applications.
The simply and intuitive interface allows high precision adjustments.
Special HF control provides 100 % rapid and precise arc ignition.
Up to 3,25 mm diameter electrode welding is possible in MMA.
MODE PROCEDURE
MMA
TIG CONTINUOUS
2 STROKE LIFT-ARC (2T)
4 STROKE LIFT-ARC (4T)
SYN
TIG PULSED
TIG SYNERGIC TIG
SPOT
2T SPOT
2T SPOT + HF
4 STROKE + HF (4T HF)
Accessories that can be connected to the unit:
• Overcut device to protect the power source from power supply voltage spikes that could dam-
age the electrical components.
2 INSTALLATION
DANGER!
Lifting and positioning
Read the warnings highlighted by the following symbols in the “General prescriptions for use”.
2.1 CONNECTIONS TO THE MAINS POWER SUPPLY
The characteristics of the mains power supply to which the equipment shall be connected are given in
the chapter entitled “TECHNICAL DATA”.
The machine can be connected to motor-generators provided their voltage is stabilised.
Connect/disconnect the various devices with the machine switched off.

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2.2 FRONT PANEL
31 4 2
○ Negative pole welding socket.[Item 1].
○ Positive pole welding socket.[Item 2].
○ Connector for logic signals of TIG torch.[Item 3].
○ Connector for gas feed hose: Torch power source [Item 4].
2.3 REAR PANEL
2
3
1
○ Welding power source ON/OFF switch [Item 1].
○ Connector for gas feed hose [Item 2]
• cylinder-generator
○ Power cable. [Item 3].
• Total length (including internal part): 2.5 m
• Number and cross section of wires: 3 x 2.5 mm2
• Type of plug supplied: Schuko

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2.4 PREPARING FOR MMA WELDING
1. Set the welding power source ON/OFF switch to “O” (unit off).
2. Plug the power cable plug into a mains socket.
3. Choose the electrode based on the type of material and thickness of the workpiece to be welded.
4. Insert the electrode in the electrode holder.
5. Connect the electrode holder clamp plug to the following welding socket: Positive pole welding
socket.
6. Connect the earth clamp plug to the following welding socket: Negative pole welding socket.
7. Connect the earth clamp to the workpiece being processed.
DANGER!
Electric shock hazard!
Read the warnings highlighted by the following symbols in the “General prescriptions for use”.
8. Set the welding power source ON/OFF switch to “I” (unit on).
9. Select the following welding mode on the user interface: MMA
10. Set the required welding parameter values on the user interface.
The system is ready to start welding.
REAR VIEW FRONT VIEW

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2.5 PREPARING FOR TIG WELDING
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 connection.
4. Open the cylinder gas valve.
5. Connect the gas hose of the welding torch to the front gas connection.
6. Connect the electrode holder clamp plug to the following welding socket: Negative pole welding
socket.
7. Choose the electrode based on the type of material and thickness of the workpiece to be welded.
8. Insert the electrode in the TIG torch.
9. Connect the earth clamp plug to the following welding socket: Positive pole welding socket.
10. Connect the earth clamp to the workpiece being processed.
11. Set the welding power source ON/OFF switch to “I” (unit powered).
12. Select the following welding mode on the user interface: DC TIG
13. 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.
14. Use the ow control valve to adjust the ow of gas as required while the gas is owing out.
15. Set the required welding parameter values on the user interface.
The system is ready to start welding.
REAR VIEW FRONT VIEW

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3 USER INTERFACE
S T O P
S T O P
Menu
Menu
Menu
Menu
SYN
SPOT
L1 L4 L5 L6 L2 L3 L7 L8 E1
D1
S1 S2 S3
L9
L10
L11
L12
L13
L14
L15
CODE SYMBOL DESCRIPTION
L1
S T O PS T O P
Overheating alarm.
Indicates tripping of the welding power source thermal protection.
Leave the unit running so that the overheated components cool as rapidly as possible.
When the unit has cooled, the welding power source will reset automatically.
- Make sure that the power required by the welding process is lower than the maximum rated
power output.
- Check that the operating conditions are in compliance with the welding power source data
plate specications.
- Check for the presence of adequate air circulation around the welding power source.
L2 When this LED illuminates the following parameter can be set: PRE-GAS TIME
L3 When this LED illuminates the following parameter can be set: SLOPE UP
L4 When this LED illuminates the following parameter can be set: PULSED CURRENT FRE-
QUENCY
L5 When this LED illuminates the following parameter can be set: WELDING CURRENT

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L6 When this LED illuminates the following parameter can be set: DOWN SLOPE
L7 When this LED illuminates the following parameter can be set: FINAL CURRENT
L8 When this LED illuminates the following parameter can be set: POST GAS TIME
L12 Illumination shows that the following function has been activated: 2 stroke procedure.
L13 Illumination shows that the following function has been activated: 4 stroke procedure.
L14
SPOT
Illumination shows that the following function has been activated: 2 stroke procedure + high
frequency arc strike (HF).
A ashing signal means the following function has been activated: 2 stroke spot procedure +
high frequency arc strike (HF).
L15 Illumination shows that the following function has been activated: 4 stroke procedure + high
frequency arc strike (HF).
L9 This LED illuminates to show that the following welding mode is selected: MMA
L10 This LED illuminates to show that the following welding mode is selected: TIG DC CONTI-
NUOUS
L11
SYN
This LED illuminates to show that the following welding mode is selected: PULSED DC TIG
A ashing signal means the following welding mode is selected: SYNERGIC PULSED DC TIG
D1 The display shows the value of the selected parameter.
S1
Menu
Menu
Menu
Menu
Press the button to select the parameter to be set.
Hold down the button for 3 seconds to gain access to the second level menu.
S2 This button selects the welding mode.
S3 This button selects the torch trigger procedure.
E1 The encoder sets the value of the selected parameter.
4 UNIT POWER-UP
Set the welding power source ON/OFF switch to “I” to switch on the unit.
FX.X The message appears on the following display: D1.
x.x= software version
First power-up or power-ups following a RESET procedure
The welding power source sets up for welding with the factory preset values.
Subsequent power-ups
The welding power source sets up for welding in the latest stable welding conguration that was active
at the time of power-off.

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5 RESET (LOAD FACTORY SETTINGS)
S T O P
S T O P
Menu
Menu
Menu
Menu
SYN
SPOT
L1 L4 L5 L6 L2 L3 L7 L8 E1
D1
S1 S2 S3
L9
L10
L11
L12
L13
L14
L15
AA
ACTIVATION ACTIVATION
The reset procedure involves complete restoration of the default values, parameters and memory set-
tings set in the factory.
All memory locations will be reset and hence all your personal welding settings will be lost!
The reset procedure is useful in the following cases:
- Too many changes made to the welding parameters so user nds it difcult to restore defaults.
- Unidentied software problems that prevent the welding power source from functioning correctly.
A
○ Set the welding power source ON/OFF switch to “O” to switch the unit off.
○Keeping both the S1 and S3 buttons pressed, set the generator power source
switch to “I” to turn on the equipment [ SIMULTANEOUS ACTIONS]
○Press both buttons S1 and S3
FAC: The message will appear on display D1
- Wait for the memory clear procedure to terminate. This action will automatically close the
menu.

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6 ALARM MANAGEMENT
This LED illuminates if an incorrect operating condition occurs.
An alarm message will appear on display D1.
Tab. 1 - Alarm messages
MESSAGE MEANING EVENT CHECKS
AL. H.
Overheating alarm
Indicates tripping of the welding
power source thermal protection.
Leave the unit running so that the
overheated components cool as
rapidly as possible.
When the unit has cooled, the
welding power source will reset
automatically.
All functions disabled.
Exceptions:
• Cooling fan.
• Make sure that the power re-
quired by the welding process is
lower than the maximum rated
power output.
• Check that the operating con-
ditions are in compliance with
the welding power source data
plate specications.
• Check for the presence of ade-
quate air circulation around the
welding power source.
7 MMA WELDING
7.1 MMA WELDING - FIRST LEVEL MENU
S T O P
S T O P
Menu
Menu
Menu
Menu
SYN
SPOT
L1 L4 L5 L6 L2 L3 L7 L8 E1
D1
S1 S2 S3
L9
L10
L11
L12
L13
L14
L15
A
ACTIVATION
B
SETTING

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A
○Press the S2 button to activate the MMA mode.
S T O PS T O P
MenuMenuMenuMenu
SYN
SPOT
L1 L4 L5 L6 L2 L3 L7 L8 E1
D1
S1
S2 S3
L9
L10
L11
L12
L13
L14
L15
A
L9 MMA
B○Using the encoder E1 to edit the value of the selected setting.
Tab. 2 - Parameters of 1st level menu: mode
SETTING MIN DEFAULT MAX NOTES
WELDING CURRENT 5 A 80 A 150 A
HOT-START - 50 % -
Set by the manufacturer.
Not user-adjustable.
Not displayed.
ARC FORCE - 50 % -
Set by the manufacturer.
Not user-adjustable.
Not displayed.
WELDING CURRENT
Output current value during welding.
HOT-START
This parameter aids electrode melting at the time of arc striking.
ARC FORCE
This parameter helps to avoid electrode sticking during welding.
During electrode fusion low conductivity parts of the coating become detached and tend to become
interposed between the electrode tip as it is fusing and the workpiece. This condition results in an in-
terruption of the arc. In addition, it may occur that the electrode comes into contact with the workpiece
creating a short circuit and consequent quenching of the arc. To avoid arc quenching the power source
therefore delivers instantaneous peak currents in correspondence with preset arc voltage thresholds.

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8 DC TIG WELDING
8.1 DC TIG WELDING - FIRST LEVEL MENU
S T O P
S T O P
Menu
Menu
Menu
Menu
SYN
SPOT
L1 L4 L5 L6 L2 L3 L7 L8 E1
D1
S1 S2 S3
L9
L10
L11
L12
L13
L14
L15
CAB
SELECTION SELECTION
ACTIVATION
D
SETTING
A
○Press the S2 button to activate the TIG mode.
S T O PS T O P
MenuMenuMenuMenu
SYN
SPOT
L1 L4 L5 L6 L2 L3 L7 L8 E1
D1
S1
S2 S3
L9
L10
L11
L12
L13
L14
L15
A
L10 CONTINUOUS TIG DC
L11 PULSED TIG DC / SYNERGIC TIG DC

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B
○Press the S3 button to select the operation of the desired torch button.
S T O PS T O P
MenuMenuMenuMenu
SYN
SPOT
L1 L4 L5 L6 L2 L3 L7 L8 E1
D1
S1
S2 S3
L9
L10
L11
L12
L13
L14
L15
B
L12 2 STROKE LIFT-ARC (2T)
L13 4 STROKE LIFT-ARC (4T)
L14 2T SPOT / 2T SPOT + HF
L15 4 STROKE + HF (4T HF)
C
○Press the S1 button to scroll the list of settings to edit.
The value associated with the selected setting appears on display D1.
L4 L5 L6
L2 L3 L7 L8
In this diagram the LED relative to the setting to be edited illuminates.
D○Using the encoder E1 , edit the value of the selected setting.
Press any button (except S1) to save the setting and quit the menu.
L4
L5 L6
L2
L3
L7
L8
Tab. 3 - Parameters of the 1st level menu: CONTINUOUS DC TIG mode
LED SETTING MIN DEFAULT MAX NOTES
L2 PRE-GAS TIME 0.0 s 0.0 s 3.0 s
- STARTING CURRENT - - - Set by the manufacturer. Not user-adjust-
able. Not displayed.
L3 SLOPE UP 0.0 s 0.0 s 20.0 s
L5 WELDING CURRENT 5 A 80 A 160 A
L6 DOWN SLOPE 0.0 s 0.0 s 20.0 s
L7 FINAL CURRENT 5 A 5 A 160 A
L8 POST GAS TIME 0.0 s 3.0 s 25.0 s

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L4 L5 L6
L2 L3 L7 L8
Tab. 4 - Parameters of the 1st level Menu in TIG DC PULSED mode.
LED SETTING MIN DEFAULT MAX NOTES
L2 PRE-GAS TIME 0.0 s 0.0 s 3.0 s
- STARTING CURRENT - - - Set by the manufacturer. Not user-adjust-
able. Not displayed.
L3 SLOPE UP 0.0 s 0.0 s 20.0 s
L5 WELDING CURRENT 5 A 80 A 160 A
L4 PULSED CURRENT FREQUENCY 0.5 Hz 125 Hz 500 Hz
L6 DOWN SLOPE 0.0 s 0.0 s 20.0 s
L7 FINAL CURRENT 5 A 5 A 160 A
L8 POST GAS TIME 0.0 s 3.0 s 25.0 s
Tab. 5 - Parameters of the 1st level Menu in TIG DC SYNERGIC PULSED mode.
LED SETTING MIN DEFAULT MAX NOTES
L2 PRE-GAS TIME 0.0 s 0.0 s 3.0 s
- STARTING CURRENT - - -
Set by the manufacturer. Not user-adjust-
able. Not displayed.
This parameter is set as a percentage
referred to the value of the following
parameter: WELDING CURRENT
L3 SLOPE UP 0.0 s 0.0 s 20.0 s
L5 WELDING CURRENT 5 A 80 A 160 A
L4 PULSED CURRENT FREQUENCY 0.5 Hz 125 Hz 500 Hz
L6 DOWN SLOPE 0.0 s 0.0 s 20.0 s
L7 FINAL CURRENT 5 A 5 A 160 A
L8 POST GAS TIME 0.0 s 3.0 s 25.0 s
WELDING CURRENT
Output current value during welding.
PRE-GAS TIME
Time of gas delivery before the arc strike.
This adjustment is required when xing points must be created or when welding in hard-to-reach posi-
tions that call for the presence of inert atmospheres before striking the arc.
Consequences of a higher value:
- This parameter allows a shielded environment to be created, thereby eliminating contaminants
at the start of the welding pass.
STARTING CURRENT
Unit current output value immediately after the arc strike.

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SLOPE UP
Time during which the current changes from the starting value to the welding value by means of a slope.
This setting is used to avoid damaging the edges of the joint with excessively high current values at the
moment of arc striking. The value of the main welding current is increased gradually in order to control
the uniformity of material deposition and weld penetration.
PULSED CURRENT FREQUENCY
Consequences of a higher value:
- Slower melt speed.
- Reduction of heat-affected zone.
DOWN SLOPE
Time during which the current changes from the welding value to the end value by means of a slope.
FINAL CURRENT
During electrode welding the parameter makes it possible to obtain a uniform deposit of ller material
from the start to the end of the welding process, closing the deposition crater with a current such as to
deposit a nal droplet of ller material.
By keeping the torch trigger pressed during the 3rd time, the crater ller current is maintained thereby
ensuring optimal crater lling, until the post gas time is started by releasing the torch trigger (4th time).
POST GAS TIME
Time of post gas delivery when the welding arc is extinguished.
Consequences of a higher value:
- More effective pickling (improved appearance of workpiece at the end of the welding pass).
- Higher gas consumption.
Consequences of a lower value:
- Lower gas consumption.
- Oxidation of electrode tip (more difcult arc strike).
SPOT TIG TIME
When the torch trigger is pressed the welding arc persists for the time set in the parameter.
Press the torch trigger again to resume the welding process.
The arc strike procedure is as follows:
Positioning of the torch with the electrode on the workpiece.
Press the torch trigger and keep it pressed.
Lift the torch slightly.
As soon as the electrode is lifted then the HF ignition starts.
The arc ignites for few hundredths of a second (time can be set up).
The result of this is a very precise, not oxidized welding spot without any plastic deformation of the
sheet.
BASE CURRENT
Pulsed wave minimum current.
Consequences of a higher value:
- Faster creation of weld pool.
- Increase of heat-affected zone.

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PEAK TIME
Time for which the current pulse is at the maximum value.
Consequences of a higher value:
- Greater weld penetration.
- Facility to make deeper cuts.
Consequences of a lower value:
- Reduction of heat-affected zone.
- Difcult to create a weld pool.
The welding parameters are available in accordance with the selected welding mode and procedure.
The table shows the settings required to enable each parameter.
Tab. 6 - Table showing enabled Welding Parameters
MENU
↓
MODE
→
SYN
PROCEDURE
→
SPOT
SPOT
SPOT
SPOT
PARAMETER
↓
1° WELDING CURRENT X X X X X X X X X X
1° PRE-GAS TIME X X X X X X
1° STARTING CURRENT X X X X X X X X X X
1° SLOPE UP X X X X X X X X X X
1° PULSED CURRENT FRE-
QUENCY X X X X
1° DOWN SLOPE X X X X X X X X X X
1° FINAL CURRENT X X X X X X X X X X
1° POST GAS TIME X X X X X X X X X X
2° SPOT WELDING TIME X X
2° BASE CURRENT X X X X X
2° PEAK TIME X X X X X

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8.2 TIG DC WELDING - SECOND LEVEL MENU
S T O P
S T O P
Menu
Menu
Menu
Menu
SYN
SPOT
L1 L4 L5 L6 L2 L3 L7 L8 E1
D1
S1 S2 S3
L9
L10
L11
L12
L13
L14
L15
A
3 sec ACTIVATION/
SELECTION
B
SETTING
A
○ Hold down the S1 button for 3 seconds to access the 2nd level menu.
○Use the encoder E1 to scroll the list of settings to be edited.
The acronym relative to the selected setting is shown on display D1.
○Press the S1 button to conrm.
The value associated with the selected setting appears on display D1.
B○Using the encoder E1 to edit the value of the selected setting.
Press any button (except S1) to save the setting and quit the menu.
Tab. 7 - Parameters of the 2nd level menu: CONTINUOUS DC TIG mode
ACRONYM SETTING MIN DEFAULT MAX
SPt SPOT WELDING TIME 0.01 s 0.1 s 10.0 s
Tab. 8 - Parameters of the 2nd level menu: PULSED TIG DC mode
ACRONYM SETTING MIN DEFAULT MAX
SPt SPOT WELDING TIME 0.01 s 0.1 s 10.0 s
b.Cu. BASE CURRENT 1% 40% 200%
PE.t. PEAK TIME 1% 50% 99%

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Tab. 9 - Parameters of the 2nd level menu: SYNERGIC DC TIG mode
ACRONYM SETTING MIN DEFAULT MAX
SPt SPOT WELDING TIME 0.01 s 0.1 s 10.0 s
b.Cu. BASE CURRENT 1% *SYN 200%
PE.t. PEAK TIME 1% *SYN 99%
*SYN: This code indicates that parameters control is synergic. The optimal value of this parameter is
set automatically by the microprocessor on the basis of the preset welding current value.
8.3 TORCH TRIGGER PROCEDURE
S T O P
S T O P
Menu
Menu
Menu
Menu
SYN
SPOT
L1 L4 L5 L6 L2 L3 L7 L8 E1
D1
S1 S2 S3
L9
L10
L11
L12
L13
L14
L15
AB
SELEZIONE
ATTIVAZIONE
A
○Premere il tasto S2 per attivare la modalità TIG desiderata.
S T O PS T O P
MenuMenuMenuMenu
SYN
SPOT
L1 L4 L5 L6 L2 L3 L7 L8 E1
D1
S1
S2 S3
L9
L10
L11
L12
L13
L14
L15
A
L10 TIG DC CONTINUO
L11 TIG DC PULSATO / TIG DC SINERGICO