Weco Discovery 200 S User manual

Cod.006.0001.1320
22/05/2019 v2.8
ENGLISH
WECO srl
Via S. Antonio, 22 - BELVEDERE
36050 TEZZE SUL BRENTA (VICENZA) ITALY
Tel.[phone] - Fax [phone]
www.weco.it - E-mail [e-mail]
Discovery 200 S
GB
Instruction manual

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CONTENTS
1INTRODUCTION........................................................................................................................................ 4
2INSTALLATION ......................................................................................................................................... 4
2.1 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK ....................................................................... 4
2.2 FRONT PANEL .......................................................................................................................................... 4
2.3 REAR PANEL............................................................................................................................................. 5
2.4 PREPARING FOR MMA WELDING ............................................................................................................ 5
2.5 PREPARING FOR TIG WELDING .............................................................................................................. 6
3COMMISSIONING...................................................................................................................................... 7
3.1 USER INTERFACE .................................................................................................................................... 7
3.2 WELDING PARAMETERS.......................................................................................................................... 8
4TECHNICAL DATA .................................................................................................................................... 9
5SPARE PARTS........................................................................................................................................ 10
6ELECTRICAL DIAGRAM ......................................................................................................................... 12
6.1 DISCOVERY 200 S .................................................................................................................................. 12
6.2 REMOTE CONTROLLER CONNECTOR .................................................................................................. 13

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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
DANGER!
This pictogram warns of danger of death or serious injury.
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.
NOTES
The figures in this manual are purely guideline and the images may
contain differences with respect to the actual equipment to which they
refer.
INTRODUCTION
Discovery 200 S is an inverter DC TIG/MMA portable welding power
source.
The solidity of the components of this unit makes it a reliable working
companion for workshop and outdoor applications.
The available DC TIG functions and digital control make this unit ideal
for maintenance, building construction, and light metalwork.
In MMA welding the Hot Start and Arc Force functions are adjustable
and they allow improved arc striking, a flatter bead and more uniform
weld.
The Anti Sticking function makes it possible to detach the electrode
rapidly from the workpiece in the event of accidental sticking.
Up to 5 mm diameter electrode welding is possible in MMA.
In DC TIG welding the pulse frequency (0.5 Hz-250 Hz) and base
current are adjustable by the welder, making it possible to focus the
arc, reduce heat transfer and limit deformation of the material.
Accessories that can be connected to the unit:
-Manual remote controller for remote adjustment of the welding
current.
-Power source trolley.
Consult your dealer for an updated list of accessories and the latest
available new products.
2INSTALLATION
DANGER!
Lifting and positioning
Read the warnings highlighted by the following symbols in the
“General prescriptions for use”.
2.1 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 9.
The machine can be connected to motorgenerators provided their
voltage is stabilised.
Connect/disconnect the various devices with the machine switched
off.
2.2 FRONT PANEL
1.
Negative pole welding socket.
2.
Positive pole welding socket.
2
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2.3 REAR PANEL
1.
Power cable.
Total length (including internal part): 3,5 m
Number and cross section of wires: 4 x 1,5 mm2
Power plug type: not supplied
2.
Welding power source ON/OFF switch.
3.
Remote controller connector.
2.4 PREPARING FOR MMA 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.
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 cable to the welding socket based on
the polarity requested by the type of electrode used.
6.
Connect the plug of the ground clamp to the welding socket on the
basis of the polarity required.
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
powered).
9.
Select the following welding mode on the user interface: MMA
10.
Set the required welding parameter values on the user interface.
When the remote controller [RC] is connected and the relative
locking screw is tightened, welding current can be adjusted using
the remote controller.
The system is ready to start welding.
Preparing for MMA (polarity to basic electrode)
2
3
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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.
Choose the electrode based on the type of material and thickness
of the workpiece to be welded.
4.
Insert the electrode in the TIG torch.
5.
Connect the torch plug to the welding socket on the basis of the
polarity required by the type of electrode in question.
6.
Connect the plug of the ground clamp to the welding socket on
the basis of the polarity required.
7.
Connect the earth clamp to the workpiece being processed.
8.
Set the welding power source ON/OFF switch to “I” (unit
powered).
9.
Select the following welding mode on the user interface: DC TIG
This model of welding machine has not been provided either with
the control for gas flow (solenoid valve) or with the torch button.
The system is ready to start welding.
LIFT-ARC WELDING
1.
Open the torch valve to let the gas out.
2.
Touch the workpiece with the torch electrode.
3.
Slowly lift the torch to strike the arc.
The WELDING CURRENT reaches the preset value.
4.
Quickly move the torch clear of the workpiece to extinguish the
welding arc.
5.
Close the torch valve to interrupt the gas flow.
Preparing for TIG (polarity for tungsten electrode)

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3COMMISSIONING
3.1 USER INTERFACE
CODE
SYMBOL
DESCRIPTION
L1
This LED illuminates to confirm the presence of power on the output sockets.
L2
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 specifications.
-Check for the presence of adequate air circulation around the welding power source.
L3
This LED illuminates to show that the following welding mode is selected: MMA
L4
This LED illuminates to show that the following welding mode is selected: PULSED DC TIG
L5
This LED illuminates to show that the following welding mode is selected: TIG DC CONTINUOUS
L6
This LED indicates that the current reference setting is imposed by the user interface.
L7
This LED indicates that the current reference setting is imposed by the remote controller.
S1
This button selects the welding mode.
S2
The button enables the device to receive the welding current control signal from a remote controller.
POT1
MMA: The potentiometer sets the value of the following parameter: HOT START
TIG: The potentiometer sets the value of the following parameter: PULSED CURRENT FREQUENCY
POT2
MMA: The potentiometer sets the value of the following parameter: ARC FORCE
TIG: The potentiometer sets the value of the following parameter: BASE CURRENT
POT3
The potentiometer sets the value of the following parameter: WELDING CURRENT

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3.2 WELDING PARAMETERS
PARAMETER
MIN
DEFAULT
MAX
NOTES
WELDING CURRENT (MMA)
5 A
-
200 A
WELDING CURRENT (TIG)
5 A
-
200 A
PULSED CURRENT FREQUENCY
0.5 Hz
-
250 Hz
BASE CURRENT
10 %
-
90 %
Percentage of welding current.
HOT-START
0 %
-
100 %
Percentage of welding current.
ARC FORCE
0 %
-
100 %
Percentage of welding current.
WELDING CURRENT
Output current value during welding.
HOT-START
This parameter aids electrode melting at the time of arc striking.
Consequences of a higher value:
-Easier arc strike.
-Increased spatter at welding start.
-Increase of strike area.
Consequences of a lower value:
-More difficult arc strike.
-Less spatter at welding start.
-Smaller strike area.
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 interruption
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.
Consequences of a higher value:
-Fluidity during welding.
-Welding arc stability.
-Greater electrode fusion in workpiece.
-More welding spatter.
Consequences of a lower value:
-The arc is extinguished more easily.
-Less welding spatter.
BASE CURRENT
Pulsed wave minimum current.
Consequences of a higher value:
-Faster creation of weld pool.
-Increase of heat-affected zone.
PULSED CURRENT FREQUENCY
Consequences of a higher value:
-Slower melt speed.
-Reduction of heat-affected zone.

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4TECHNICAL DATA
Directives applied
Waste electrical and electronic equipment (WEEE)
Electromagnetic compatibility (EMC)
Low voltage (LVD)
Restriction of the use of certain hazardous substances (RoHS)
Construction standards
EN 60974-1; EN 60974-10 Class A
Conformity markings
Equipment compliant with European directives in force
Equipment suitable in an environment with increased hazard of electric shock
Equipment compliant with directive WEEE
Equipment compliant with directive RoHS
Supply voltage
3 x 400 Va.c. ± 15 % / 50-60 Hz
Mains protection
10 A Delayed
Zmax
This equipment complies with IEC 61000-3-12 provided that the maximum permissible system
impedance is less than or equal to 238 mΩ at the interface point between the user's supply
and the public system. It is the responsibility of the installer or user of the equipment to
ensure, by consultation with the distribution network operator if necessary, that the equipment
is connected only to a supply with maximum permissible system impedance less than or equal
to 238 mΩ.
Dimensions ( L x D x H )
400 x 160 x 260 mm
Weight
10 kg
Insulation class
H
Protection rating
IP23S
Cooling
AF: Air-over cooling (fan assisted)
Static characteristic
MMA
Drooping characteristic
TIG
Drooping characteristic
Current and voltage adjustment range
MMA
5 A / 20.2 V - 200 A - 28.0 V
TIG
5 A / 10.2 V - 200 A - 18.0 V
Welding current / Working voltage
MMA
40 % (40° C)
200 A - 28.0 V
60 % (40° C)
170 A - 26.8 V
100 % (40° C)
130 A - 25.2 V
TIG
40 % (40° C)
200 A - 18.0 V
60 % (40° C)
170 A - 16.8 V
100 % (40° C)
130 A - 15.2 V
Maximum input power
MMA
40 % (40° C)
6.7 kVA
60 % (40° C)
5.7 kVA
100 % (40° C)
4.1 kVA
TIG
40 % (40° C)
4.4 kVA
60 % (40° C)
3.6 kVA
100 % (40° C)
2.1 kVA
Maximum supply current
MMA
40 % (40° C)
9.6 A
60 % (40° C)
8.1 A
100 % (40° C)
5.8 A
TIG
40 % (40° C)
6.4 A
60 % (40° C)
5.2 A
100 % (40° C)
3.1 A
Maximum effective supply current
MMA
40 % (40° C)
6.1 A
60 % (40° C)
6.3 A
100 % (40° C)
5.8 A
TIG
40 % (40° C)
4.0 A
60 % (40° C)
4.0 A
100 % (40° C)
3.1 A
No-load voltage (U0)
MMA
61 V
TIG
61 V
Reduced no-load voltage (Ur)
TIG
13 V

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5SPARE PARTS

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N°
CODE
DESCRIPTION
1
005.0001.0004
BELT
2
011.0006.0031
HANDLE
3
011.0000.0121
COVER PLATE
4
012.0003.0000
INTERNAL FRAMEWORKS
5
050.0013.0091
POWER BOARD
6
044.0004.0001
INDUCTANCE
7
011.0003.0011
DEFLECTOR PLATE
8
010.0006.0041
FRONT PLASTIC
9
021.0001.0260
FIXED SOCKET
10
050.5027.0000
FRONT PANEL
11
014.0002.0006
KNOB WITH CUP WITHOUT INDICATOR
12
014.0002.0004
KNOB WITH CUP WITHOUT INDICATOR
13
050.0004.0013
FILTER BOARD
14
011.0003.0001
LOWER COVER
15
042.0003.0010
POWER TRANSFORMER
16
015.0001.0005
HEAT SINK
17
032.0002.2003
ISOTOP DIODE
18
050.0001.0012
SNUBBER BOARD
19
040.0003.1070
THERMAL CUT-OUT
20
050.0001.0119
CAPACITOR BOARD
21
032.0001.3616
THREE PHASE BRIDGE RECTIFIER
22
045.0000.0007
CABLE CLAMP
23
045.0002.0016
NEOPRENE CABLE
24
010.0006.0009
COMPLETE REAR PLASTIC PANEL
25
040.0001.0015
BI-POLE SWITCH
26
013.0003.0000
REAR PANEL
27
022.0002.0005
REMOTE CONTROL WIRING
28
041.0004.0300
HALL EFFECT SENSOR
29
003.0002.0002
FAN
30
011.0003.0002
FANS SUPPORT

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6ELECTRICAL DIAGRAM
6.1 DISCOVERY 200 S

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6.2 REMOTE CONTROLLER CONNECTOR
Welding side
cod. 021.0004.0602
Remote Controller
2 kOhm-10 kOhm potentiometer

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