Linde Ryval 181 BASIC aXe User manual

Linde AG, Linde Gas Deutschland © Ryval 181-221 aXe Manual EN 03

MIG/MAG WELDING MACHINES

Ryval 181 BASIC aXe

Ryval 221 BASIC aXe

INSTRUCTION MANUAL

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Content:

1. INTRODUCTION ............................................................................................. 3

2. SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 3

3. CONDITIONS OF USE ...................................................................................... 7

4. TECHNICAL DATA ........................................................................................... 8

5. ACCESSORIES ................................................................................................. 8

6. DESCRIPTION OF THE APPLIANCE .................................................................. 9

7. GETTING STARTED ....................................................................................... 11

8. WELDING ..................................................................................................... 14

9. ROUTINE MAINTENANCE & INSPECTION ...................................................... 19

1 . STATEMENT OF WARRANTY ........................................................................ 2

11. DISPOSAL ..................................................................................................... 21

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1. INTRODUCTION

Congratulations on your new Linde AG, Linde Gas Deutschland product. We

are proud to have you as our customer and will strive to provide you with the

best service and reliability in the industry.

This Operating Manual has been designed to instruct you on the correct use

and operation of your Linde AG, Linde Gas Deutschland product. Your

satisfaction with this product and its safe operation is our ultimate concern.

Therefore please take the time to read the entire manual, especially the

Safety Precautions. They will help you to avoid potential hazards that may

exist when working with this product.

Read and understand this entire Manual and your employer’s safety

practices before installing, operating, or servicing the equipment. While the

information contained in this Manual represents the Manufacturer's best

judgement, the Manufacturer assumes no liability for its use.

Ryval 181 and Ryval 221 BASIC aXe are three phase sturdy welding

machines for MIG MAG welding.

The machines are designed to produce maximum power output combined

with high reliability and efficiency.

2. SAFETY INSTRUCTIONS AND WARNINGS

1. OPERATION AND MAINTENANCE OF WELDING EQUIPMENT CAN BE

DANGEROUS AND HAZARDOUS TO YOURHEALTH.

2. Arc welding produces intense electric and magnetic emissions that may

interfere with the proper function of cardiac pacemakers, hearing aids, or

other electronic health equipment. Persons who work near arc welding

applications should consult their medical health professional and the

manufacturer of the health equipment to determine whether a hazard

exists.

3. Once the packing has been opened, make sure that the machine is not

damaged. If in any doubt, call the service centre.

4. This equipment must only be used by qualified personnel.

5. During installation, any electric work must only be carried out by trained

personnel.

6. The machine must be used in a dry place with good ventilation.

7. Make sure that no metal dust can be drawn in by the fan inside the

machine, as this could cause damage to the electronic circuits.

8. It is prohibited to connect more than one generator in series or in parallel.

9. When installing the machine, follow the local regulations on safety.

10. The position of the machine must allow easy access by the operator to

the controls and connectors.

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11. When the welding machine is operating, all its covers and doors must

be closed and well fixed.

12. Do not expose the welding machine to direct sunlight or to heavy rain.

This equipment conforms to protection rating IP23S.

13. The operator must wear gloves, clothes, shoes, and a helmet or a

welder’s helmet, which protect and are fire-resistant in order to protect

him against electric shock, flashes and sparks from cutting.

14. The operator must protect his eyes with safety visor or mask designed

for welding, fitted with standard safety filters. He should also be aware

that during arc welding ULTRAVIOLET RADIATION is emitted. Therefore

it is vital that his face is also protected from radiation. Ultraviolet rays

produce the same harmful effect as sun burning on unprotected skin.

15. The operator is obliged to warn anyone near the welding area of the

risks that welding involves and to arrange to provide adequate protection

equipment.

16. Keep all fumes and gases from the breathing area.

17. Keep your head out of the fume plume.

18. Use an air-supplied respirator if ventilation is not adequate to remove

all fumes and gases.

19. The kinds of fumes and gases from the plasma arc depend on the kind

of metal being used, coatings on the metal, and the different processes.

You must be very careful when welding any metals which may contain

one or more of the following:

Antimony Chromium Mercury

Nickel Cobalt Arsenic

Barium Copper Selenium

Beryllium Lead Silver

Cadmium Manganese Vanadium

20. Always read the Material Safety Data Sheets (MSDS) that should be

supplied with the material you are using. These MSDSs will give you the

information regarding the kind and amount of fumes and gases that may

be dangerous to your health.

21. It is very important to arrange for sufficient ventilation, especially when

welding in enclosed spaces. We suggest using suitable fume extractors to

prevent the risk of intoxication by fumes or gas generated by the welding

process.

22. Noise can cause permanent hearing loss. Welding arc processes can

cause noise levels to exceed safe limits. You must protect your ears from

loud noise to prevent permanent loss of hearing.

23. To protect your hearing from loud noise, wear protective ear plugs

and or ear muffs. Protect others in the workplace.

24. Noise levels should be measured to be sure the decibels (sound) do

not exceed safe levels.

25. The operator must ensure all flammable materials are removed from

the work area to avoid any risk of fire.

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26. The operator must NEVER weld containers that have previously

contained petrol, lubricants, gas or similar flammable materials, even if

the container has been empty for a considerable time. THERE IS A VERY

HIGH RISK OF EXPLOSION.

27. The operator must be aware of all the special regulations which he

needs to conform to when cutting in enclosed spaces with a high risk of

explosion.

28. To prevent electric shock, we strongly suggest the following rules:

29. Do not work in a damp or humid environment.

30. Do not use the machine if its cables are damaged in any way.

31. Make sure that the earthing system of the electric equipment is

correctly connected and operational.

32. The operator must be insulated from the metal components connected

to the return wire.

33. The earthing of the piece being worked could increase the risk of injury

to the operator.

34. EN 60974-1 Standard: Open-circuit voltage. During the operation of

the machine, the highest voltage, with which it is possible to come into

contact, is the open-circuit voltage between the clamps.

35. The maximum open-circuit voltage of the plasma machines is

established by national and international standards (EN 60974-1)

depending on the type of current to be used, on its waveform and on the

hazards arising from the work place. These values are not applicable to

the strike currents and those for stabilisation of the arc that could be

above it.

36. The open-circuit voltage, for as many adjustments as possible, must

never exceed the values relating to the various cases shown in the

following table:

Case

Working conditions Open-circuit voltage

1 Places with increased

risk of electric shock

DC current: 113V

peak value

AC current: 68V

peak value and 48V

effective

2 Places without increased

risk of electric shock

DC current: 113V

peak value

AC current: 113V

peak value and 80V

effective

3 Torches held

mechanically with

increased protection for

the operator

DC current: 141V

peak value

AC current: 141V

peak value and

100V effective

4 Plasma cutting DC current: 500V

peak value

37. In case 1, the dc machines with rectifier must be built in such a way

that, in case of a fault developing in the rectifier (for example open circuit,

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short circuit or lack of power), the permitted values cannot be exceeded.

The welding machines of this type can be marked with the symbol:

38. Before opening the machine switch off the machine and disconnect it

from the power socket.

39. Only personnel authorised by this company can carry out maintenance

on the machine.

PROTECTIVE UTTILITIES

1. Welding helmet with filter shade at least 10

2. Welding gloves

3. Welding apron and cloth

4. Welding boots

RISK OVERVIEW

1. Risk of electric shock.

2. Ultraviolet light and light radiation

3. Risk of inhaling gas fumes and dust particles

4. Burns

5. Noise

NOTE

1. It is forbidden to operate a machine with damaged insulation of the

welding torch or supply cable.

2. Never operate the machine taken down or damaged covers.

3. It is forbidden to operate the machine in wet environments and outdoors

in rain or snow.

4. Ensure proper grounding clamping pliers, which also reduces the risk of

electric shock.

5. Use prescribed protective utilities, keep them dry.

6. Arc welding produces intense electric and magnetic emissions that may

interfere with the proper function of cardiac pacemakers, hearing aids,

or other electronic health equipment. Persons who work near plasma

arc cutting applications should consult their medical health professional

and the manufacturer of the health equipment to determine whether a

ha ard exists.

7. Never aim the torch against the eyes, body or other person.

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3. CONDITIONS OF USE

1. This equipment must only be used by qualified personnel.

2. During installation, any electric work must only be carried out by trained

personnel.

3. Device complies with IEC 61000-3-12.

4. Do not expose the plasma machine to direct sunlight or to rain or snow.

This equipment conforms to protection rating IP23S.

5. Place the machine the way that the cooling air can enter the vents without

restriction to. It is necessary to ensure that no impurities, especially metal

particles are not drawn into the machine.

6. Welding machine in terms of interference suppression is intended

primarily for industrial premises. In the case of use of other areas may be

need for special measures (see EN 60974-10).

7. The machine must be protected against

a) Moisture and rain and snow

b) Mechanical damage

c) Draft and any ventilation of neighbouring machine

d) Excessive overloading - crossing technical parameters

e) Rough handling

ELECTROMAGNETIC COMPATIBILITY

The welding device is in terms of interference designed primarily for

industrial areas. It meets the requirements of EN 60974-10 class A and it

isn’t designed for using in residential areas, where the electrical energy is

supplied by public low-voltage power supply network. It can be here potential

problems with ensuring of electromagnetic compatibility in this areas, due to

interference caused by power lines as well as the radiated interference.

During operation, the device may be the source of interference.

Caution

We warn users, that they are responsible for possible interference from

welding.

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4. TECHNICAL DATA

Ryval 181 Ryval 221

Mains voltage V/Hz 3 x 400/50 3 x 400/50

Mains protection A 10 @ 16 @

Max. input power 1 A 8,9 12,1

Max. effective current 1eff A 5,9 7,7

Welding current range A 30 - 180 30 - 210

Open-circuit voltage U20 V 19,3 - 37,7 20,8 - 43,6

Welding current (DC=100%) 2 A 130 150

Welding current (DC=60%) 2 A 150 170

Welding current (DC=x%) 2 A 40%=180 40%=210

Voltage steps 7 7

nsulation class F F

Protection P 23S P 23S

Standards EN 60974-1; EN 60974-10 class A

Dimensions (w x l x h) mm 474 x 888 x 561 474 x 888 x 561

Weight kg 61 65

Wire speed m/min

1 - 17 1 - 17

Spool diameter mm 300 300

Spool weight kg 18 18

5. ACCESSORIES

DELIVERED WITH THE MACHINE

1. Earthing cable 3m with a clamp

2. Feed roll 0,6 - 0,8 mm for ALF 181; 0,8 - 1,0 mm for ALF 221

3. Gas hoses

4. Reduction for the wire spool

ACCESSORIES TO ORDER

1. Wire cleaner

2. CO2 Gas pre heating cable

3. Reduction valve KU 5, K 2

4. Gas cylinder

5. Torch consumables

6. Earthing cable 4 - 5 m

7. Feed rolls 0,6-0,8, for carbon steels, aluminium, flux core wires

8. Welding torches

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6. DESCRIPTION OF THE APPLIANCE

MAIN PARTS

Fig. 1 - Main parts

A1 ON OFF Switch

A2 Voltage switch

A3 LED ON Indicator

A4 Work leads

A5 LED over heating indicator

A6 Wire speed potentiometer

A7 EURO connector

A8 Gas heater connector

A9 Solenoid Valve – gas connector

A10 Mains cable

A11 Chain for fixing the gas cylinder

A12 Wire Feeder

A13 Spool Holder

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CONTROL PANEL - OVERVIEW

Fig. 2 - Control panel

A1 PCB - encoder ON OFF Switch

A2 Voltage switch

A3 LED ON Indicator

A5 LED over heating indicator

P1 Wire speed potentiometer

P2 Spot time potentiometer

P3 Interval time potentiometer

WIRE FEEDER

Fig 3 – Wire feeder

Pos. Description

E1 Fixing shaft

E2 Pressure arm

E3 Liner- Feeder

E4 EURO connector

E5 Roll, Plastic cup

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