Most PONTIG 202 AC/DC MOST Manual de usuario
User Manual for Welding Rectier
PONTIG 202 AC/DC MOST
User Manual
Version 1.0k of 11.06.2019
Original manual
Catalogue no: 52 00 005421
Attention! Every person using or responsible for the maintenance of this device should
read the entire contents of this user’s manual before starting work. This will optimize the
use of device potential.
Attention! A copy of this User Manual should be stored near the device and available for
operator at all times.
User Manual
Version 1.0k of 11.06.2019
Original manual
PONTIG 202 AC/DC MOST -2-
Table of Contents
1. Health and Safety Manual
2. Maintenance
3. Technical description
4. Installation and use
5. Technical data and device completion
6. Device construction
7. PONTIG 202 AC/DC control panel
7.1 Description of the device buttons
7.2 Welding parameter settings
7.3 Description of the control panel operation
7.4 Saving parameters
8. TIG welding
8.2 TIG DC Pulse welding
8.3 TIG AC welding
8.4 TIG AC Pulse welding
9. TIG buttons operating modes
10. MMA coated electrode welding
11. Problems occurring during welding
12. Electrical scheme
13. EU Declaration Of Conformity
14. Recycling
User Manual
Version 1.0k of 11.06.2019
Original manual
PONTIG 202 AC/DC MOST -3-
Thank you for buying the Inverter Rectier PONTIG 202 AC/DC MOST.
Prior commencing work please familiarize yourself with the user manual. The device PONTIG
202 DC MOST was designed for DC TIG welding with argon shield (steel and stainless steel),
and for AC welding (aluminium and its alloys) or for coated electrodes MMA. We do believe that
this product will meet your requirements.
1. Health and Safety Manual
WARNING: The device can not be used for the purpose of pipe defrosting!
] Information contained on the icons placed on the device:
Use and maintenance of welding equipment may be dangerous. The user must
observe health and safety rules and regulations. Welding and cutting machines
may be used only by qualied personnel. Follow your local rules and regulations
on working with that type of devices and prevention of accidents.
Prior to starting your work remove all ammables from the welding area. Welding
inside tanks previously used as ammable liquid storage (e.g. petrol) is forbidden.
Place all combustible materials away from welding spatter.
Do not expose the device to rain or water vapour and do not spray water over it.
Do not weld without proper eye protection. Pay attention to providing safety for
bystanders against welding radiation.
Use ventilation and lters in order to remove welding fumes from the work site.
Use individual lters if the ltering/ventilation system does not operate correctly or
is not available.
Stop your work immediately after nding damage to the power cords. Do not to-
uch the damaged cords. Prior a repair or maintenance disconnect the device from
power source. Never use the device with damaged power cords.
Keep a re extinguisher close to the welding location. After nishing work
check the work station against re hazards.
Never try to x a damaged gas reducer on your own. In case of malfunction repla-
ce the reducer to a fully functional one.
User Manual
Version 1.0k of 11.06.2019
Original manual
PONTIG 202 AC/DC MOST -4-
ATTENTION: The following user manual should be read prior installing and starting
the device. OSH manual should be known to every welder and employee responsible
for equipment maintenance.
PRELIMINARY REMARKS
Commissioning and normal operation are possible only after carefully reading the following
manual. Arc welding requires compliance with the requirements for electric arc welding and re
regulations. The welder should be supplied with protective clothing and equipment in
accordance with current regulations. It is necessary to use a set of personal protective
equipment (PPE) in accordance with provisions of the Council Directive 2016/425/EEC. The
personal protective equipment includes: welding mask with a protective lter, welding gloves,
protective apron, welding clothing, and leather shoes. Despite the high technical standard of
the device, the personnel should represent considerable discipline in approach to health and
safety requirements to protect against harmful and health hazardous factors developed from
welding technology.
OPERATING CONDITIONS
This device can operate under severe conditions. It is however important to apply simple
preventive measures to ensure long and reliable work:
- do not place or use this device on an inclined surface (of more than 15º),
- do not use the device for pipe defrosting,
- the device must be located in a place where the free circulation of clean
air is ensured without any restriction of airow to and from the fan. When the device is
connected to the network, do not cover it with, for example, paper or cloth;
- minimize the amount of dirt and dust that can get into the device,
- device housing has an IP21S protection. Keep it dry and do not place on
wet surfaces or in a puddle,
- do not use the device for welding the tanks previously used for storing ammable substances.
ENVIRONMENTAL CONDITIONS
Range of air temperatures for
- operation: from-10ºC to +40ºC
- storage and transportation: from -25ºC to +55ºC
- Relative air humidity: up to 50% at +40ºC; up to 90% at +20ºC.
GASES AND FUMES
TIG and MMA welding modes produce harmful gases and fumes containing ozone and
hydrogen as well as oxides or metal particles. Therefore, the welding work station should be
tted with very good ventilation (dust and smoke extraction or airy location). Metal surfaces
intended for welding should be free from chemical contamination, especially degreasers
(solvents),
that decompose during welding process and produce toxic gases. Welding of galvanized,
cadmium-coated or chromium-plated parts is permitted only when a suction and ltering device
is tted, and with introduction of fresh air to the welding work station.
User Manual
Version 1.0k of 11.06.2019
Original manual
PONTIG 202 AC/DC MOST -5-
RADIATION
Ultraviolet emission radiated when welding is harmful to eyesight and skin. Therefore a welding
mask with protective lters is required. Welding work station should meet certain requirements
and include:
• adequate lighting system,
• xed or movable protection screens, governing bystanders against radiation eects (depen-
ding on requirements),
radiation eects,
• placed in a room with appropriate wall colour (absorption of UV radiation)
FIRE PROTECTION
Welding work station should be located at a safe distance from ammables placed especially
on the oor or walls. All ammables need re protection against hot metal drops. It is
recommended to t the work station with re blankets and re extinguishers.
PROTECTION AGAINST ELECTRIC SHOCK
It is unacceptable to connect the device to an improper installation or to an installation
with unveried zeroing eciency. Removing the outer covers at a time the device is connected
to the electricity network, as well as the use of the device with covers removed
IS PROHIBITED. It is not allowed to work on a suspended device e.g. using gantry or
crane. Maintenance and repair works should be carried out by authorized personnel in
compliance with the applicable safety conditions.
2. Maintenance
ATTENTION: In order to carry out any repair or maintenance work, it is recommended
to contact your nearest RYWAL-RHC technical support (a list of authorized service
shops is available on the last page of the manual).
In the event of noticing any damage, the welder should stop working, should disconnect the
device from power supply and report it to direct supervisor or appropriate service -
RYWAL-RHC technical support.
General maintenance (daily)
- check the condition of cables and connections, replace if necessary,
- check condition of welding torch and connection with welding cable, replace if necessary,
- check condition and operation of the cooling fan; keep the cooling air inlet and outlet openings
clean,
- keep the device clean.
Periodic maintenance (every 3 months at least)
Periodic maintenance frequency can be increased depending on working conditions
and the intensity of use.
Maintenance:
- using a stream of dry air (at low pressure) remove the dust from the outer parts of the casing
and from inside of the welding device,
- check and tighten all the screws,
- check the state of all electrical contacts and correct if necessary.
User Manual
Version 1.0k of 11.06.2019
Original manual
PONTIG 202 AC/DC MOST -6-
ATTENTION: Device must be disconnected from electrical network before performing
any maintenance or service work. After each repair, perform respective check
to ensure safe use.
Mandatory device checks
According to the Labour Code provisions: „All responsibility for the safe use of machinery and
equipment shall be borne by the owner.” This results in the obligation to perform periodic and
post-repair checks and inspections of equipment.
Periodic tests are carried out at least once a year (legal basis EN ISO 17662 clause 4.2), and
post-repair tests after each repair that restored welding functionality (legal basis: EN 60974-4
clause 4.6).
All above services are performed by the technical support of RYWAL-RHC.
3. Technical description
The PONTIG 202 AC/DC is an inverter welding rectier for TIG welding in an argon shield
(arc ignition by HF ionizer) or for MMA with coated electrode (Stick). The device has excellent
welding properties and has a wide application range. It may be used for welding:
a/ MMA electrode welding - in direct current (DC)
Recommended electrodes from 1.6 to 3.25 mm in diameter. Electrodes with a rutile or alkaline
coating (idling voltage DC Uₒ = 60V), for steel or stainless steel,
b/ TIG DC welding method
Ignition of the arc by the HF ionizer, gas opened automatically by the electrovalve in the device.
For welding stainless steel or ordinary steel, recommended tungsten electrode diameter 1.6 or
2.4 mm You can weld in a continuous or pulsed current.
c/ TIG AC method
Ignition of the arc by the HF ionizer, gas opened automatically by the electrovalve in the device.
Welding of aluminium or its alloys, recommended diameter of tungsten electrode 1,6 or
2.4 mm Available functions of AC balance, negative / positive AC and
pulsed voltage regulation.
The device is protected against overheating by a thermal sensor. It is made
in accordance with the IEC 60974-1 standard, „Arc welding equipment. Part 1: Welding power
sources”.
4. Installation and use
- The user is responsible for connecting the device in accordance with the manufacturer
instructions. In the event of electromagnetic interference, the user should remove the cause
after prior consultation with the manufacturer.
- Before using the equipment, the welder should estimate the possible impact of disturbances
on the environment, in particular the presence of persons with pacemakers or hearing aids.
- Work with a power generator is acceptable, but it must meet certain requirements. It is
recommended to use a unit with a power of min. 8 kVA with asynchronous generator. If the
generator does not provide adequate power, this results in lowering the arc parameters or
turning o the rectier.
User Manual
Version 1.0k of 11.06.2019
Original manual
PONTIG 202 AC/DC MOST -7-
Parameter Unit Value
Electrical power supply V/Hz 1x230/50-60
Power tolerance % +15/-15
Welding current range A TIG: 10-200
MMA: 10-160
Welding current set point Stepless
Overload protection A 16 delayed
Work cycle
MMA DC A/%
160/30
114/60
88/100
Work cycle
TIG A/%
200/25
129/60
100/100
MMA electrode diameter mm 1,6-3,25
Sockets for connecting
welding cables.
35/50 (large)
Power factor cos 0,7
Power consumption kW 8,2 (MMA)
6,0 (TIG)
Eciency % 85
Plug Schuko 16A
Insulation class F
Protection class IP 21S
Standard EN 60974-1
Mark CE
Dimensions mm 502x218x382
Weight kg 9,0
(17 kg carton of accessories)
Catalogue no. 52 00 005421
5. Technical data and device completion
Table 1: Technical data PONTIG 202 AC/DC MOST.
Device assembly:
PONTIG 202 DC is delivered in a cardboard box with gas hoses, mass cables and MMA
welding electrode. TIG torch is an optional accessory - see Accessories.
Accessories:
TIG 26 Most 4m Torch (Pontig 210 /202) 56 01 032622
TIG 26 Most 8m Torch (Pontig 210/202) 56 01 032624
Welding trolley WUS HD 50 03 003942
User Manual
Version 1.0k of 11.06.2019
Original manual
PONTIG 202 AC/DC MOST -8-
6. Device construction
Figure 1: Construction of PONTIG 202 AC/DC MOST
1. ON/OFF switch (rear side)
2. Gas connection (rear side)
3. Top handle
4. Control panel (see section 7)
5. Current socket (+)
6. TIG torch control socket
7. TIG torch gas socket
8. Current socket (-)
9. Power cable with plug (rear side)
8
2
9
1
7
3
6
5
4
7. Pontig 202 AC/DC Control panel
Figure 2: Control panel for Pontig 202 AC/DC MOST
1. Display and unit diodes
2. Welding method selection
3. Operating mode of the TIG
torch
4. Knob
5. Additional functions
6. Welding parameter curve
User Manual
Version 1.0k of 11.06.2019
Original manual
PONTIG 202 AC/DC MOST -9-
Figure 3: 3-digit display (1) and unit diodes
Figure 4: Selection of welding method (2)
Figure 5: Operating mode of the TIG torch (3)
Display
of parameter
values or error
codes
Current in Ampers [A]
Unit of time - seconds
AC Balance or pulse
rate (in percent)
Frequency of AC or
pulse frequency (Hz)
Function
selection (down)
(12)
SPOT welding
(15)
Selection of
welding mode
(16)
User Manual
Version 1.0k of 11.06.2019
Original manual
PONTIG 202 AC/DC MOST -10-
Figure 6: Welding parameters diagram (6)
Figure 7: Additional functions (5)
Pre-ow time (17)
On the left side of the panel with additional functions there is a knob (4) to switch between
parameters. After pressing we can set the parameter value, which is conrmed by pressing (4)
again.
TIG Spot welding
time or MMA
ArcForce (20)
Upslope time
(19)
Initial current
(18)
Background
current I2 (28)
Balance (27) Post-ow
time (26)
Final cur-
rent (25)
Downslope
time (24)
Pulse frequency [Hz]
or current peak time
(23)
AC
frequency
(22)
Welding current
I1 (21)
Remote control or local control
(29)
Incorrect current value and elec-
trode diameter (30): diode lights
up yellow
Selection of electrode diameter
(31)
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