Weco Discovery 300 User manual

Cod.006.0001.1920
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ENGLISH
WECO srl
Via S. Antonio, 22 - BELVEDERE
36056 TEZZE SUL BRENTA (VICENZA) ITALY
Tel.[phone] - Fax [phone]
www.weco.it - E-mail [email protected]
Discovery300
GB
Instruction manual

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CONTENTS
1INTRODUCTION ............................................................................................................................................... 4
2INSTALLATION ................................................................................................................................................ 5
2.1 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK ........................................................................... 5
2.2 FRONT PANEL.................................................................................................................................................. 5
2.3 REAR PANEL.................................................................................................................................................... 5
2.4 PREPARING FOR MMA WELDING.................................................................................................................. 5
2.5 PREPARING FOR TIG WELDING .................................................................................................................... 7
3COMMISSIONING............................................................................................................................................. 9
3.1 USER INTERFACE ........................................................................................................................................... 9
3.2 UNIT POWER-UP............................................................................................................................................ 10
3.3 RESET (LOAD FACTORY SETTINGS) .......................................................................................................... 10
3.4 SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE)............................................................... 10
3.5 ALARMS MANAGEMENT ............................................................................................................................... 11
4WELDING SETTINGS..................................................................................................................................... 12
4.1 WELDING PARAMETERS .............................................................................................................................. 12
4.2 ELECTRODE WELDING (MMA) ..................................................................................................................... 12
4.3 DC TIG WELDING........................................................................................................................................... 12
5TECHNICAL DATA......................................................................................................................................... 13
5.1 DISCOVERY 300............................................................................................................................................. 13
6SPARE PARTS ............................................................................................................................................... 14
6.1 DISCOVERY 300............................................................................................................................................. 14
7ELECTRICAL DIAGRAM................................................................................................................................ 17
7.1 DISCOVERY 300............................................................................................................................................. 17
7.2 REMOTE CONTROLLER CONNECTOR........................................................................................................ 19

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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.
LEGEND
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
This professional and rugged welding power source for DC MMA and
TIG welding with exceptional arc characteristics is designed to
operate in harsh environmental conditions in the fields of professional
maintenance, shipyards and offshore, building construction and heavy
fabrication.
The combination of digital control and excellent welding with cellulosic
electrodes is ideal for hydraulic applications and welding work on oil
pipelines and in the petrochemical industry.
Up to 4 mm diameter electrode welding is possible in MMA.
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.
The fan is turned on only during welding, at the end of the welding
process it remains on for a fixed period of time according to welding
conditions.
The fan is nonetheless controlled by specific thermal sensors that
guarantee a correct cooling of the machine.
Accessories/ancillary devices that can be connected to the unit:
-Manual remote controller for remote adjustment of the welding
current.
Consult your dealer for an updated list of accessories and the latest
available new products.

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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 13.
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.
2.3 REAR PANEL
1.
Remote controller connector.
2.
Power cable.
Total length (including internal part): 5,0 m
Number and cross section of wires: 4 x 2,5 mm2
Power plug type: not supplied
3.
Welding power source ON/OFF switch.
4.
Mains protection ON LED.
This LED illuminates if an incorrect operating condition occurs:
-absence of a phase in the power supply line.
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.
1
2
1
2
3
4

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(polarity to basic electrode)

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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.

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(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
Illumination shows that the following function has been activated: VRD (reduced output voltage).
The no-load voltage between the welding sockets is switched from U0to Ur(see technical data).
L3
Illuminates to show a value in the following unit of measurement: VOLTS
L4
Illuminates to show a value in the following unit of measurement: AMPERES
L5
This LED indicates that the current reference setting is imposed by the remote controller.
L6
This LED illuminates to show that the following welding mode is selected: MMA
L7
This LED illuminates to show that the following welding mode is selected: CELLULOSE
L8
This LED illuminates to show that the following welding mode is selected: TIG DC CONTINUOUS
D1
Parameters/functions setting: The display shows the selected parameter.
Welding: The display shows the effective amperes or volts value during welding.
S1
Welding: This button selects the parameter to be shown on the following display: D1
Possible choices: (A) Effective welding current - (V) Effective welding voltage
Parameters/functions setting: This button selects the parameter to be shown on the following display: D1
Possible choices: (A) Effective welding current - (V) Effective welding voltage
S2
Press and release: the button enables the device to receive the welding current control signal from a remote controller.
Keep the button pressed while powering on the power source: the button opens the SETUP menu.
S3
This button selects the welding mode.
E1
Welding: The encoder sets the value of the following parameter: WELDING CURRENT
Parameters/functions setting: The encoder provides the facility to alter the selected parameter.
POT1
MMA: The potentiometer sets the value of the following parameter: HOT START
POT2
MMA: The potentiometer sets the value of the following parameter: ARC FORCE

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3.2 UNIT POWER-UP
Set the welding power source ON/OFF switch to “I” to switch on the unit.
AL.H.
The message appears on the following displays: D1
First power-up or power-ups following a RESET procedure
The welding power source sets up for welding with the factory presets.
Subsequent power-ups
The welding power source sets up for welding in the latest stable welding configuration that was active at the time of power-off.
3.3 RESET (LOAD FACTORY SETTINGS)
The reset procedure involves complete restoration of the default values, parameters and memory settings 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 finds it difficult to restore defaults.
-Unidentified software problems that prevent the welding power source from functioning correctly.
Set the welding power source ON/OFF switch to “O” to switch the unit off.
S2
S3
Hold down both buttons simultaneously.
Set the welding power source ON/OFF switch to “I” to switch on the unit.
SIMULTANEOUS ACTIONS
rEC
The message appears on the following displays: D1
Wait for the memory clear procedure to terminate.
3.4 SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE)
Set the welding power source ON/OFF switch to “O” to switch the unit off.
S2
Hold down the button.
Set the welding power source ON/OFF switch to “I” to switch on the unit.
SIMULTANEOUS ACTIONS
Vrd
The acronym relative to the setting to be edited appears on the following displays: D1
E1
Using the encoder, edit the value of the selected setting.
Exit without confirmation
S2
Press the button.
This action will automatically close the menu.
Exit with confirmation
Press any button (except S2).
This action will automatically close the menu.
Tab. 1 - Setup settings
ACRONYM
SETTING
MIN
DEFAULT
MAX
Vrd
OUTPUT VOLTAGE REDUCTION
oFF
oFF
on
U.EL.
LONG ARC VOLTAGE MMA
37
*SYN
65
*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. This value can be displayed but it is not user-adjustable.
When SYN is installed, to display the synergic value press the following button: S1
OUTPUT VOLTAGE REDUCTION
Voltage must be reduced when maximum output voltage of the power source cannot exceed a limit value set by specific standards on the use of
welding power sources in shipyards, offshore platforms, etc.
LONG ARC VOLTAGE MMA
This parameter inhibits power output when the potential between electrode and workpiece exceeds the preset threshold level.
Consequences of a higher value: the welding arc persits even with a significant distance between the electrode and the workspiece.
Consequences of a lower value: faster exit from weld.

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3.5 ALARMS MANAGEMENT
An alarm message appears on the following display: D1
Tab. 2 - Alarm messages
MESSAGE
MEANING
EVENT
CHECKS
AL. HEA.
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.
-Cooler (if
switched on).
-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.
Phase missing alarm
Indicates the absence of a phase in the power
supply line.
The message appears when the mains protection
activation LED switches on.
All functions
disabled.
Exceptions:
-Cooling fan.
-Check if the equipment power supply line has all the phases.
If the problem persists:
-qualified technical personnel are required for
repair/maintenance jobs.

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4WELDING SETTINGS
4.1 WELDING PARAMETERS
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.
4.2 ELECTRODE WELDING (MMA)
S3
Use this button to select one of the following welding modes:
MMA
CELLULOSE
Tab. 3 - Parameters of the 1st level menu: MMA mode
PARAMETER
MIN
DEFAULT
MAX
NOTES
WELDING CURRENT
MAXIMUM CURRENT WITH REMOTE CONTROLLER
10 A
80 A
300 A
HOT-START
0 %
-
100 %
The value is calculated as a percentage of the preset welding current.
ARC FORCE
0 %
-
200 % (MMA)
400 % (CEL)
The value is calculated as a percentage of the preset welding current.
The value is limited to 300A max.
4.3 DC TIG WELDING
S3
This button serves to select the following welding mode:
TIG DC CONTINUOUS
Tab. 4 - Parameters of the 1st level menu: CONTINUOUS DC TIG mode
PARAMETER
MIN
DEFAULT
MAX
WELDING CURRENT
5 A
80 A
300 A

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5TECHNICAL DATA
5.1 DISCOVERY 300
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 WEEE directive
Equipment compliant with RoHS directive
Supply voltage
3 x 400 Va.c. ± 15 % / 50-60 Hz
Mains protection
20 A 500V Delayed
Zmax
This equipment complies with IEC 61000-3-12 provided that the maximum permissible system
impedance is less than or equal to 38 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 38 mΩ.
Dimensions ( L x D x H )
460 x 230 x 325 mm
Weight
20.8 kg
Insulation class
H
Protection rating
IP23S
Cooling
AF: Air-over cooling (fan assisted)
Maximum gas pressure
0,5 MPa (5 bar)
Static characteristic
MMA
Drooping characteristic
TIG
Drooping characteristic
Current and voltage adjustment range
MMA
10 A / 20.4 V - 300 A / 32.0 V
TIG
5 A / 10.2 V - 300 A / 22.0 V
Welding current / Working voltage
MMA
40 % (40° C)
300 A - 32.0 V
60 % (40° C)
230 A - 29.2 V
100 % (40° C)
200 A - 28.0 V
TIG
50 % (40° C)
300 A - 22.0 V
60 % (40° C)
250 A - 20.0 V
100 % (40° C)
210 A - 18.4 V
Maximum input power
MMA
40 % (40° C)
13.3 kVA –10.7 kW
60 % (40° C)
9.9 kVA –7.9 kW
100 % (40° C)
8.4 kVA –6.6 kW
TIG
50 % (40° C)
10.3 kVA –7.9 kW
60 % (40° C)
8.4 kVA –6.2 kW
100 % (40° C)
6.7 kVA –4.8 kW
Maximum supply current
MMA
40 % (40° C)
19.1 A
60 % (40° C)
14.3 A
100 % (40° C)
12.3 A
TIG
50 % (40° C)
14.8 A
60 % (40° C)
12.2 A
100 % (40° C)
9.4 A
Maximum Effective Supply Current
MMA
40 % (40° C)
12.1 A
60 % (40° C)
11.1 A
100 % (40° C)
12.3 A
TIG
50 % (40° C)
10.5 A
60 % (40° C)
9.5 A
100 % (40° C)
9.4 A
No-load voltage (U0)
MMA
76 V
TIG
76 V
Reduced no-load voltage (Ur)
MMA
9 V
TIG
9 V

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6SPARE PARTS
6.1 DISCOVERY 300

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N°
CODE
DESCRIPTION
1
014.0002.0012
KNOB WITH CAP + INDICATOR
2
014.0002.0010
KNOB WITH CAP + INDICATOR
3
050.5046.0000
FRONT PANEL
4
010.0006.0038
FRONT PLASTIC
5
021.0001.0259
FIXED SOCKET
6
050.0001.0119
PRIMARY CAPACITOR BOARD
7
011.0008.0029
LATERAL PLATE
8
040.0003.0060
TERMAL SWITCH
9
050.0003.0036
POWER BOARD
10
040.0003.1270
THERMAL CUT-OUT 70°C L=200mm
11
011.0008.0021
UPPER PLATE
12
016.0010.0001
BOARDS SUPPORT GUIDE
13
050.0002.0039
MAINS FILTER BOARD
14
050.0002.0057
POWER SUPPLY CONTROL BOARD
15
011.0000.0161
COVER PLATE
16
041.0006.0004
AUXILIARY TRANSFORMER
17
010.0006.0034
REAR PLASTIC PANEL
18
040.0001.0017
THREE-POLE SWITCH
19
022.0002.0190
LED WIRING
20
013.0012.0002
REAR PANEL
21
016.4107.0001
LED HOLDER
22
045.0000.0050
CABLE CLAMP
23
045.0002.0019
NEOPRENE CABLE
24
022.0002.0005
REMOTE LOGIC CABLE
25
011.0008.0010
EXTERNAL FAN SUPPORT
26
003.0002.0003
FAN
27
011.0008.0011
INTERNAL FAN SUPPORT
28
040.0003.1170
THERMAL CUT-OUT 70°C L=300mm
29
045.0006.0058
DIODE-DIODE BRACKET
30
050.0003.0044
SNUBBER BOARD
31
045.0006.0061
DIODES-TRANSFORMER COPPER BRACKET
32
032.0002.2003
ISOTOP DIODE
33
015.0001.0006
HEAT SINK
34
044.0004.0025
OUTPUT INDUCTOR
35
010.0007.0002
POWER TRANSFORMER
36
050.0001.0031
OUTPUT FILTER BOARD
37
011.0008.0001
LOWER COVER
38
016.0009.0003
RUBBER FOOT
39
041.0004.0300
HALL EFFECT SENSOR

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7ELECTRICAL DIAGRAM
7.1 DISCOVERY 300

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

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