ENEL 150AC Manuale utente

ENel

Sp. z o. o. - WROCŁAW

DESIGN AND MANUFACTURE OF POWER

ELECTRONIC DEVICES

INVERTER WELDING MACHINE

ENEL150AC

USER MANUAL

DEALER:

1. INTRODUCTION

This manual contains information that will allow to take full advantage of

ENEL150AC welding machine operation values and enable its safe use.

All users are encouraged to read the user manual.

2. APPLICATION

ENEL150AC welding machine is a modern direct and alternating current

source designed mainly for TIG welding and with coated electrodes (MMA) of

all types (ER-, EA-, EB-, ES-, ...) with diameters from ∅1.6 to ∅3.2. Due to

the high open circuit voltage (95V) and very good welding properties, the

device also allows welding with cellulose coated electrodes which are used,

among others, for pipelines welding.

When equipped with appropriate TIG welding torch it is possible to weld steel

and its alloys and copper and its alloys using TIG welding (welding with a

non-consumable electrode - mostly tungsten electrode in an inert gas shield,

such as argon). The ignition of the arc is non-contact (HF) or contact by

scratch. The remote control of the welding current is possible in all operating

modes.

A microprocessor controller ensures precision welding, repeatable setting of

many parameters, and simple usage.

Due to the small dimensions and weight, and resistance to large voltage

fluctuations, the ENEL150AC welder is particularly useful for operation in

difficult field conditions when installing any type of welded structures,

pipelines, tanks, etc.

The device is designed for operation at ambient temperature from -10°C up

to +40°C and relative humidity up to 90% at temperature of + 20°C.

3. DESCRIPTION

ENEL150AC welding machine is an inverter direct current source operating in

the frequency range above the audio frequency. This current source is

characterised by good dynamics and a smooth and stable arc. It is

lightweight, of small dimensions, resistant to large fluctuations of the mains

voltage. The connecting, control and indicating elements are located on the

front panel. On the rear panel there are: the power switch, the power cord,

the fan, the rating plate and the gas valve connection used to supply

shielding gas from the cylinder.

Control and indicating elements of the welder are shown in Fig. 1.

Figure1

The welder is equipped with a digital display (1), indicating the values of set

parameters, a knob to adjust parameter values(2), operating mode switch (5),

parameters switch (3), ignition mode switch (4), selector of direct current or

alternating current polarity ( 6), and indicators.

There are four operation modes available to select with the button (5) (Fig. 1):

1) welding with coated electrodes (MMA) - the red light should indicate

The welding current is adjustable in the range of 5 to 130A with a

resolution of 1A. The rectifier is provided with the ANTISTICK feature

facilitating electrode unsticking when it adheres to the works being welded

(when the electrode adheres to elements being welded longer than 1.5

seconds, the welding current is automatically switched off, so electrode

detaching is not difficult).

The voltage polarity (DC+ or DC-) of an electrode we can select with a button

(6).

There are possible two operation modes:

a) with an automatic open circuit voltage reduction to the safe value of

approx. 12V. This mode is automatically set when the power is turned on

and after changing from another mode to MMA mode - it is signalled by

continuous illumination of the LED indicating welding current Is.

b) without automatic open circuit voltage reduction. Open circuit voltage is

sustained at a level of 95V. This operation mode can be selected by

pressing the parameters switch button (3). It is indicated by blinking of the

LED indicating welding current Is. Press the button (3) again to return to

the operation with automatic open circuit voltage reduction.

When the welding machine is equipped with a remote control module, it is

possible to remotely change the welding current during performing the weld.

2) TIG 2T welding with direct current (DC-) (2 Step trigger) - the red light

should indicate

The following parameters can be set within given ranges:

•Is[A] - welding current in amperes adjustable in the range of 5-150A with a

resolution of 1A

•Tn[s] - welding current rise time in seconds adjustable in the range 0.1-5s

with a resolution of 0.1s

•To[s] - welding current fall time in seconds adjustable in the range 0.1-20s

with a resolution of 0.1s

•Ib[%] - base current adjustable as a percentage of the welding current Is

within the range 10-100% with a resolution of 1%. If the value of the basic

current is set to 100%, the welding current will have a constant value

equal to the set value of Is. If the value of the basic current is different

from 100%, we get pulsating current with the following parameters:

welding current will pulsate with the frequency fp and the duty cycle TH[%]

(see below)

•TH[%] - duration of current pulses of the value Is as a percentage of the

signal pulse period within the range 1-99%. TH parameter is adjustable

only when the set value of the base current Ib is different from 100%

•fp[Hz] - the welding current pulse frequency in Hz, adjustable in the range

0.1-50Hz. fp parameter is adjustable only when the set value of the

base current Ib is different from 100%

•Tg[s] - time of gas flow after the arc extinction in seconds, adjustable in

the range 1-25s with the resolution of 1s

Examples of pulsating current signals for different settings of fp, Ib, TH

You can select the method of ignition using HF button (4):

CONTACT IGNITION - LAMP (9) IS OFF

The welding process is initiated by pressing a control button on the grip.

When the button is pressed the gas valve is opened. After releasing the

button (while welding don't hold the button pressed!) you can ignite

the arc by touching the workpiece and slightly lifting an electrode (the arc

ignition occurs at the moment of lifting an electrode).

NON-CONTACT IGNITION - LAMP (9) IS ON

The welding process is initiated by pressing a control button on the grip.

When the button is pressed the gas valve is opened. Releasing the button

starts the ionizer - spark-over between an electrode and a workpiece

should initiate ignition of the arc. If ignition of the arc does not occur within

2.5s ionizer is turned off and ignition process must be repeated.

Following the arc ignition the welding current increases during the set

rise time Tn from minimum value (5A) to the set value of Is. Short

pressing (and releasing) the control button starts the process of

decreasing the welding current from the Is value to the minimum value

(during the set fall time To). If the control button is pressed briefly during

the current fall phase, welding current again will increase to the Is value.

When the current reaches the minimum value, welding current is turned

off and the arc is extinguished. Shielding gas flows still during the set time

Tg, then the gas valve is being closed. The welding process has been

completed.

Ib=50

TH=20

Tp=1/fp

Ib=10

TH=80

3) TIG 4T welding with direct current (DC-) (4 Step trigger) - the red light

should indicate

The following parameters can be set within given ranges:

•Is[A] - welding current in amperes adjustable in the range of 5-150A with a

resolution of 1A

•Ip[%] - initial current adjustable as a percentage of the welding current Is

within the range 5-50% with a resolution of 1%.

•Tn[s] - welding current rise time in seconds adjustable in the range 0.1-5s

with a resolution of 0.1s

•To[s] - welding current fall time in seconds adjustable in the range 0.1-20s

with a resolution of 0.1s

•Ib[%] - base current adjustable as a percentage of the welding current Is

within the range 10-100% with a resolution of 1%. If the value of the basic

current is set to 100%, the welding current will have a constant value

equal to the set value of Is. If the value of the basic current is different

from 100%, we get pulsating current with the following parameters:

welding current will pulsate with the frequency fp and the duty cycle TH[%]

(see below)

•TH[%] - the duration of current pulses of the value Is as a percentage of

the signal pulse period within the range 1-99%. TH parameter is

adjustable only when the set value of the base current Ib is different

from 100%

•fp[Hz] - the welding current pulse frequency in Hz, adjustable in the range

0.1-50Hz. fp parameter is adjustable only when the set value of the

base current Ib is different from 100%

•Ik[%] - final current adjustable as a percentage of the welding current Is

within the range 5-50% with a resolution of 1%.

•Tg[s] - time of gas flow after the arc extinction in seconds, adjustable in

the range 1-25s with the resolution of 1s

You can select the method of ignition using HF button (4):

CONTACT IGNITION - LAMP (8) IS OFF

The welding process is initiated by pressing (and releasing) a control

button on the grip. When the button is pressed the gas valve is opened.

After releasing the button (while welding don't hold the button

pressed!) you can ignite the arc by touching the workpiece and slightly

lifting an electrode (the arc ignition occurs at the moment of lifting an

electrode).

NON-CONTACT IGNITION - LAMP (9) IS ON

The welding process is initiated by pressing a control button on the grip.

When the button is pressed the gas valve is opened. Releasing the button

starts the ionizer - spark-over between an electrode and a workpiece

should initiate ignition of the arc. If ignition of the arc does not occur within

2.5s ionizer is turned off and ignition process must be repeated.

The arc ignites with the current Ip. Pressing again (and releasing) the

control button starts the process of increasing the welding current from the

Ip value to the set welding current Is (during the time Tn). Pressing once

again (and releasing) the control button starts the process of decreasing

the welding current from the Is value to the Ik value (during the set time

To). The last fourth pressing (and releasing) the control button causes the

arc extinguish. If the control button is pressed briefly during the current fall

phase, welding current again will increase to the Is value. Shielding Gas

flows still during the set time Tg, then the gas valve is being closed. The

welding process has been completed.

4) REMOTE CONTROL WHILE TIG 2T AND 4T WELDING

If the TIG welding torch is equipped with 2 buttons, it is possible to change

the welding current during performing the weld. One of the buttons is for

increasing and the second for decreasing of current setting (you can

freely assign buttons). Holding down one of these buttons changes the

welding current during welding. Changes of welding current are reflected

on the welder display (1). The welding current could be changed by 1A

within the range from 5 to 50A, and within the range 50-150A by 5A. The

change of welding current made during welding is stored and the next

cycle of welding will be done using the new settings.

5) TIG PUNKT welding with direct current (DC-) - the red light should

indicate

The following parameters can be set within given ranges:

•Is[A] - welding current in amperes adjustable in the range of 5-150A with a

resolution of 1A

•Tn[s] - welding current rise time in seconds adjustable in the range 0.1-5s

with a resolution of 0.1s

•To[s] - welding current fall time in seconds adjustable in the range 0.1-20s

with a resolution of 0.1s

•Tpunkt[s] - duration of spot welding in seconds adjustable in the range

0.01 - 10s with a resolution of 0.01s

•Tg[s] - time of gas flow after the arc extinction in seconds, adjustable in

the range 1-25s with the resolution of 1s

You can select the method of ignition using HF button (4):

CONTACT IGNITION - LAMP (9) IS OFF

The welding process is initiated by pressing (and releasing) a control

button on the grip. When the button is pressed the gas valve is opened.

After releasing the button (while welding don't hold the button

pressed!) you can ignite the arc by touching the workpiece and slightly

lifting an electrode (the arc ignition occurs at the moment of lifting an

electrode).

NON-CONTACT IGNITION - LAMP (9) IS ON

The welding process is initiated by pressing a control button on the grip.

When the button is pressed the gas valve is opened. Releasing the button

starts the ionizer - spark-over between an electrode and a workpiece

should initiate ignition of the arc. If ignition of the arc does not occur within

2.5s ionizer is turned off and ignition process must be repeated.

Following the arc ignition the welding current increases during the set

rise time Tn from minimum value (5A) to the set value of spot welding

current Is. The current Is flows during the set time Tpunkt and then

automatically starts the process of decreasing the welding current from

the Is value to the minimum value (during the set time To). When the

current reaches the minimum value, welding current is turned off and the

arc is extinguished. Shielding gas flows still during the set time Tg, then

the gas valve is being closed. When the gas flows (after extinction of the

arc), it is possible to initiate the next spot welding process.

6) TIG 2T and 4T welding with alternating current (AC) - the green light

should indicate

AC welding is possible only for TIG welding. Select AC. Using the knob (2)

(Fig. 1) select the diameter of the electrode E1.6, E2.4 or E3.2.

The following parameters can be set for AC within given ranges:

•fac[Hz] - frequency of the alternating current adjustable in the range 50 to

200 Hz with a resolution of 1 Hz

•BAL[%] - balance, the relationship between the positive and negative half

of current signal, adjustable in the range from -70 to +70% with resolution

of 1%. A value of 0% means that positive and negative current half

durations are equal. The balance allows you to control the heat flow

between tungsten electrode and a workpiece material. If the balance is

positive, it means that the positive part of the cycle lasts longer than the

negative one and more heat emits from an electrode than welded

material.

•I+[%] - current of the positive part of the cycle adjustable as a percentage

of the welding current Is within the range 10-100% with a resolution of 1%.

The lights indicating selection of these parameters illuminate in green.

Examples of alternating current signals for different settings of fac, BAL, I+

Every welding mode has its own independent set of parameters

stored in the memory of the control circuit. After the welding machine

is turned on all automatically memorized sets of parameters as well

as the last used operating mode are restored.

The main switch of welding machine (green) is located on the rear panel -

backlight of the key indicates that the power cord is connected to the mains.

After the welding machine is turned on, the green indicator (7) (Fig. 1), digital

display and the red light indicating the last selected operating mode light up.

I+=100

Tac=1/fac

BAL=-50

Tac=1/fac

BAL=0

I+=50

A welder has a thermal protection to protect certain components against

excessive overheating. Activation of this protection is indicated by the lamp

(8) (Fig. 1) shining yellow.

7) PROTECTION AGAINST UNAUTHORIZED USER

There is a possibility of a securing a welding machine against unauthorized

user with a PIN code. After enabling this function, each time the power is

turned on a welding machine requires entering a proper three-digit PIN code.

After entering the correct code device switches to the normal operation. If you

enter a wrong code, the device waits for entering the correct code.

Entering three times of incorrect code disables the welding machine -

unlocking is possible only in the ENEL service center.

To enable the security function, follow these steps:

⇒When you turn the power on, press and hold the P and HF buttons until

"HLP" symbol turns off (approx. 2 seconds) and you will see the firmware

version number. After releasing the buttons the display will show "P.0 0".

⇒Press P button - the display shows "0 - -", set the first digit with the knob

and accept it with P button; the display shows "- 0 -", set the second digit

with the knob and accept it with P button; the display shows "- - 0", set

the third digit with the knob and accept it with P button.

⇒You see "P.0 0" on the display - when you press M button, the device

starts normal operation.

The PIN code was introduced - every time the power is on you must enter the

code in the following way:

⇒The display shows "0 - -", set the first digit with the knob and accept it

with P button; the display shows "- 0 -", set the second digit with the

knob and accept it with P button; the display shows "- - 0", set the third

digit with the knob and accept it with P button.

To disable the security function, follow these steps:

⇒When you turn the power on press and hold the P and HF buttons until

"HLP" symbol turns off (approx. 2 seconds) and you will see the firmware

version number. After releasing the buttons you have to enter the correct

PIN code.

⇒When the correct code is entered the display shows "P.0 0".

⇒Press P button - the first digit of the code is displayed, set 0 with the

knob and accept it with P button; the second digit of the code is

displayed, set 0 with the knob and accept it with P button; the third digit

of the code is displayed, set 0 with the knob and accept it with P button -

the display shows "P.0 0" - when you press M button, the device starts

normal operation.

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