NAVIGATOR 2500 / 3000BrugsanvisningInstruction manualBetriebsanleitungManuel d'instructionBruksanvisningManuale d'istruzioneKäyttöohjeManual de instrucciones

Valid from 0641 50113117 H

DK – INDHOLDSFORTEGNELSE: - Advarsel / Elektromagnetisk støjudstråling ...............................................................3- Maskinprogram / Tilslutning og brug .........................................................................4- Betjeningsvejledning ..................................................................................................6- Fejlsøgning...............................................................................................................11- Tekniske data / Vedligeholdelse..............................................................................12- Garantibestemmelser...............................................................................................12- Reservedelsliste.......................................................................................................83

GB – CONTENTS: - Warning / Electromagnetic emissions .....................................................................13- Product programme / Connection and operation ....................................................14- Initial instructions......................................................................................................16- Location of errors .....................................................................................................21- Technical specifications / Maintenance...................................................................22- Warranty regulations ................................................................................................22- Spare parts list..........................................................................................................83

D – INHALTSVERZEICHNIS: - Warnung / Elektromagnetische Störungen..............................................................23- Produktübersicht / Anschluß und Inbetriebnahme ..................................................24- Allgemeine Bedienung .............................................................................................26- Fehlersuche..............................................................................................................31- Technische Daten / Wartung ...................................................................................32

Garantiebedingungen...............................................................................................32- Ersatzteilliste ............................................................................................................83

F – INDEX: - Avertissement / Emission de bruit électromagnétique............................................33- Gamme de machines / Raccordement et mise en service .....................................34- Entretien ...................................................................................................................35- Notice d'utilisation.....................................................................................................36- Recherche des pannes............................................................................................41- Données techniques / Warranty ..............................................................................42- Liste des pièces de rechange ..................................................................................83

S – INNEHÅLLSFÖRTECKNING: - Varning / Elektromagnetisk störning........................................................................43- Maskinprogram / Anslutning och användning .........................................................44- Användarinstruktioner ..............................................................................................46- Felsökning ................................................................................................................51- Teknisk data / Underhåll ..........................................................................................52- Garantibestämmelser...............................................................................................52- Reservdelslista .........................................................................................................83

I – INDICE: - Attenzione / Emissioni elettromagnetiche ...............................................................53- Gamma di prodotti / Collegamento e montaggio.....................................................54- Instruzioni iniziali ......................................................................................................56- Ricerca guasti...........................................................................................................61- Dati tecnici / Manutenzione......................................................................................62- Condizioni di garanzia..............................................................................................62- Elenco parti di ricambio............................................................................................83

FIN – SISÄLLYSLUETTELO: - Varoitus / Sähkömagneettiset häiriöt.......................................................................63- Tuoteohjelma / Kytkentä ja käyttöönotto .................................................................64- Käyttö........................................................................................................................66- Vianetsintä................................................................................................................71- Tekniset tiedot / Huolto ............................................................................................72- Takuuehdot ..............................................................................................................72- Varaosaluettelo ........................................................................................................83

E – ÍNDICE: - Atención / Emisiones electromagnéticas.................................................................73- Gama de productos / Conexión y uso .....................................................................74- Instrucciones iniciales.............................................................................................76- Identificación de fallos ............................................................................................81- Datos técnicos / Mantenimiento..........................................................................82- Garantía ...................................................................................................................82- Spare parts list..........................................................................................................83

EC DECLARATION OF CONFORMITYMIGATRONIC A/SAggersundvej 339690 FjerritslevDenmark

hereby declare that our machine as stated belowType: NAVIGATOR 2500 / 3000As of week 40, 2001conforms to directives 73/23/EEC and 89/336/EEC.European Standards: EN/IEC60974-1

EN/IEC60974-10Issued in Fjerritslev on 1st October 2001.

Peter RoedManaging director

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ENGLISH

Electromagnetic emissions and the radiation of electromagnetic disturbances

This welding equipment for industrial and professional use is inconformity with the European Standard EN/IEC60974-10. Thepurpose of this standard is to prevent the occurrence of situationswhere the equipment is disturbed or is itself the source ofdisturbance in other electrical equipment or appliances. The arcradiates disturbances, and therefore, a trouble-free performancewithout disturbances or disruption, requires that certain measuresare taken when installing and using the welding equipment. The usermust ensure that the operation of the machine does not occa-sion disturbances of the above mentioned nature.The following shall be taken into account in the surrounding area:1. Supply and signalling cables in the welding area which are

connected to other electrical equipment.2. Radio or television transmitters and receivers.3. Computers and any electrical control equipment.4. Critical safety equipment e.g. electrically or electronically con-

trolled guards or protective systems.5. Users of pacemakers and hearing aids etc.6. Equipment used for calibration and measurement.

7. The time of day that welding and other activities are to be carriedout.

8. The structure and use of buildings.

If the welding equipment is used in a domestic establishment it maybe necessary to take special and additional precautions in order toprevent problems of emission (e.g. information of temporary weldingwork).

Methods of reducing electromagnetic emissions:1. Avoid using equipment which is able to be disturbed.2. Use short welding cables.3. Place the positive and the negative cables close together.4. Place the welding cables at or close to floor level.5. Remove signalling cables in the welding area from the supply

cables.6. Protect signalling cables in the welding area, e.g. with selective

screening.7. Use separately-insulated mains supply cables for sensitive

electronic equipment.8. Screening of the entire welding installation may be considered

under special circumstances and for special applications.

WARNINGArc welding and cutting can be dangerous to the user, people working nearby, and the surroundings if the equipment is handled orused incorrectly. Therefore, the equipment must only be used under the strict observance of all relevant safety instructions. Inparticular, your attention is drawn to the following:

Electricity- The welding equipment must be installed according to safety regulations and by a properly trained and qualified person. The machine

must be connected to earth through the mains cable.- Make sure that the welding equipment is correctly maintained.- In the case of damaged cables or insulation, work must be stopped immediately in order to carry out repairs.- Repairs and maintenance of the equipment must be carried out by a properly trained and qualified person.- Avoid all contact with live components in the welding circuit and with electrodes and wires if you have bare hands. Always use dry

welding gloves without holes.- Make sure that you are properly and safely earthed (e.g use shoes with rubber sole).- Use a safe and stable working position (e.g. avoid any risk of accidents by falling).

Light and heat emissions- Protect the eyes as even a short-term exposure can cause lasting damage to the eyes. Use a welding helmet with suitable radiation

protection glass.- Protect the body against the light from the arc as the skin can be damaged by welding radiation. Use protective clothes, covering all parts

of the body.- The place of work should be screened, if possible, and other persons in the area warned against the light from the arc.

Welding smoke and gases- The breathing in of the smoke and gases emitted during welding is damaging to health. Make sure that any exhaust systems are working

properly and that there is sufficient ventilation.

Fire hazard- Radiation and sparks from the arc represent a fire hazard. As a consequence, combustible materials must be removed from the place of

welding.- Working clothing should also be secure against sparks from the arc (e.g. use a fire-resistant material and watch out for folds and open

pockets).- Special regulations exist for rooms with fire- and explosion hazard. These regulations must be followed.

Noise- The arc generates acoustic noise according to welding task. In some cases, use of hearing aids is necessary.

Dangerous areas- Special consideration must be taken when welding is carried out in closed areas or in heights where there is a danger of falling down.

Positioning of the machine- Place the welding machine so there is no risk that the machine will tip over.- Special regulations exist for rooms with fire- and explosion hazard. These regulations must be followed.

Use of the machine for other purposes than it is designed for (e.g. to unfreeze water pipes) is strongly deprecrated. If the occasion shouldarise this will be carried out without responsibility on our part.

Read this instruction manual carefullybefore the equipment is installed and in operation

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MACHINE PROGRAMMENAVIGATOR 2500/3000 is a line of welding machines,especially designed for welding in e.g. the sheet metaland tube industries.There are several versions of the machine: MMA, TIGDC and TIG AC/DC. DC stands for welding with directcurrent. AC stands for welding with alternating current.All versions are designed for welding with coatedelectrodes and are equipped with antifreeze, adjust-able arc power and hot-start. Moreover, the machinecan be used for pulse welding with the possibility ofsetting of pulse time, pause time and base amp.In TIG welding the following functions are included:- adjustable slope up and slope-down- adjustable gas pre-flow and gas post-flow time- adjustable start Amp and stop Amp- adjustable reduced current- choice of 2-times-, 4-times- and spot welding- LIFTIG- HF-TIG- connection and disconnection of pilot arc- AC-balance- AC welding frequency- digital display- current control from the TIG torch handle- remote control facility (option)- programming of up to ten welding settings

In LIFTIG ignition the TIG arc is ignited after makingcontact between the workpiece and the tungstenelectrode, after which the trigger is activated and thearc established by lifting the electrode away from theworkpiece.In HF-TIG ignition the TIG arc is ignited without con-tact. A high-frequency (HF) impulse initiates the arcwhen the trigger is activated.

Transportation equipmentThe MIGATRONIC programme includes a transporttrolley which can be used for all versions.

Welding hosesThe machine can be equipped with TIG weldinghoses, electrode holders and return current cablesfrom the MIGATRONIC programme. If an adjustableTIG torch is used, the welding current can be adjustedfrom the torch.

External adjustment (option)Remote control and foot control units can be deliveredto NAVIGATOR 2500/ 3000.

Torch cooling module (option)An integrated torch cooling module can be deliveredwhich enables use of watercooled TIG welding torchesfrom the MIGATRONIC programme.

CONNECTION AND OPERATIONLift instructions

Dispose of the product according to localstandards and regulations.www.migatronic.com/goto/weee

ConfigurationMIGATRONIC disclaims all responsibility for damagedcables and other damages related to welding withundersized welding torch and welding cablesmeasured by welding specifications e.g. in relation topermissible load.

Important!In order to avoid damage to plugsand cables, good electric contact isrequired when connecting the workreturn cable and welding torch to themachine.

WarningConnection to generators can damage the weldingmachine.When connected to a welding machine, generatorscan produce large voltage pulses, which can damagethe welding machine. Use only frequency and voltagestable generators of the asynchronous type.Defects on the welding machine arisen due toconnection of a generator are not included in theguarantee.

Mains connectionNAVIGATOR 2500/3000 is designed for connection tothe mains voltage mentioned on the type plate. Afterthe mains plug has been connected to the mains cable(6) the machine is ready for use. Please note that allcable connections must be made by authorised andqualified staff. Switch on and off the machine bymeans of the breaker on the rear of the machine (5).

Gas connectionConnect the machine to the gas system by means of agas flow control.

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Diffusion-free gas hosesThis welding machine has been mounted with a PVCgas hose, which is sufficient for general weldingtasks. We recommend that the machine is equippedwith diffusion-free gas hoses in these special caseswhere large demands have been made on gaspurity. Diffusion sealed gas hoses result in lessmoisture to the protection gas. These special gashoses can be ordered as special equipment andshould be mounted on the supply side out to thesolenoid valve.

Connection of welding cablesConnect the welding cables and the return currentcable to the front of the machine (1 and 2). Pleasenote that the plug must be turned 45 degrees afterinsertion into the socket - otherweise the plug can bedamaged due to excessive contact resistance.Connect always the TIG connection in the minus (-)tap (2) and the return current cable in the plus (+) tap(1).The control signals from the TIG torch are transformedto the machine through the circulary 7-poled plug (3).When the plug has been assembled please secure itby turning the "circulator" clockwise. Connect the gashose to the quick connection (4).Electrodes are marked with a polarity on the packing.Mount the electrode tongs in accordance with thismarking to the plus/minus taps of the machine (1 and2).

Connection of external adjustment (option)Connect the remote control unit on the rear of themachine on the circulary 8-poled plug (7).

Control of cooling liquidIf the machine is delivered with an integrated torchcooling module, it will be necessary to inspect thecooling liquid level by means of the level control (8).Refillment of cooling liquid takes place through thefiller neck (9).

Usage of the machine (NAVIGATOR 3000)When welding, heating of various components of themachine takes place and during breaks these com-ponents will cool down again.It must be ensured that the air intake and outlet are notblocked.

It is not possible to overload the machine in normaluse, and there is no need for cooling down periods atcurrent settings up to 190 Amps. When the machine isset for welding currents higher than these, there will bea need for periods during which the machine can cooldown.The length of these periods depends on the currentsetting, and the machine should not be switched offduring cooling to avoid stop of the cooling fan. If theperiods for cooling down during use of the machineare not sufficiently long, the overheating protection willautomatically stop the welding process and the yellowLED will come on. The yellow LED switches off whenthe machine has cooled down sufficiently, and themachine is ready for welding.Max. load is:

100 % max. load 190 A 60 % max. load 240 A 25 % max. load 300 A

60 % max. load when MMA welding means that acooling period of 4 minutes after welding for 6 minutesis required at a current setting of 240 A, 10 minutesbetween start of each welding period must be cal-culated in connection with the above table.

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INITIAL INSTRUCTIONS

All "parameters" are set by the use of only one controlknob. These parameters include current, pulse time,slope-up time, etc.This control knob is positioned below a digital displaywhich shows the value of the parameter being set. Theunit of measurement of the parameter is shown at theright hand side of the digital display.Change or view the setting of a parameter by pressingthe knob of the parameter in question until the LED atthe parameter symbol is lit.Also the parameters with on/off function, e.g. TIGignition method, can be chosen by pressing the knobof the parameter in question. The chosen function isshown with a LED.

Storage of parametersThe machine memorises all settings when the mainsinput voltage is switced off, thus ensuring that thesame machine settings are available when themachine is switched on again.The exact adjustments in the two welding processes(MMA electrode and TIG) are stored as well, so thatshifting from one welding process to another does notrequire a new current setting.

Setting of the machineThe following describes in detail the operation of themachine.

Welding currentOn pressing this keypad the control knob can be

used to set the welding current unless however that,the machine has been set to external adjustment.

After the welding process has stopped, the adjustedcurrent is shown on the display, during welding, how-ever, the actual welding current is shown. During pulsewelding an average welding current is automaticallyshown when shifting between welding current andbase current becomes faster than possible viewing.

Setting of welding jobsThis function enables storage of often used

machine settings and shift from one complete settingto another. By pressing the keypad the display showsa "P" and a number: "1", "2" etc. Each number is asetting of all parameters and functions of the machine.It is therefore possible to have one setting for eachwelding job for which the machine is used. The controlknob is used for shifting between these settings.During shifting it is possible to see both process andthe other on/off-functions in each setting. Change ofsetting is not possible during the welding process. Thesetting selected is effected by releasing the keypad. Itis possible to store 10 settings in MMA and 10 settingsin TIG.

Welding voltageThe welding voltage indicator is illuminated for

reasons of safety and in order to show if there isvoltage on the electrode or the TIG torch.

Units of measurement of the parameterUnits of measurement of the parameter shown inthe digital display.

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OverheatingThe overheating indicator is alight or flashes on

and off with a yellow light if welding is interrupted dueto overheating of the machine. The indicator remainsilluminated 5 seconds after the overheating error isremoved. Please read chapter conc. "fault indification".

Mains errorThe mains error indicator is illuminated with red if themains voltage is too high or low. The indicator remainsilluminated 5 seconds after the mains error iscorrected so short-term errors on the mains voltagecan be noticed by the welder. Please see paragraphconc. fault indification.

Welding processThis display is used to select the

welding process, e.g. MMA electrode or TIG. Thefunction is fixed during welding, and shift from TIG toMMA is not possible before the post-flow has beenfinished.

MMA electrodeMMA electrode welding has been selected.

TIGTIG welding has been selected.

Function of the torch trigger(The trigger method)

This display is used to decide whether the start/stopmethod of the TIG welding process is to be two-times,four-times (latching), or spot. Welding process meansthe phases: pre-flow, slope-up, welding with adjustedcurrent, if necessary, reduced current, slope-down andpost-flow. It is not possible to change trigger methodduring the welding process.

Two-timesThe welding process begins by pressing the torchtrigger. Welding continues until the trigger is releasedagain which effects the slope-down period. Themachine can be reactivated during slope-down andgas post-flow.

Four-timesThe welding process begins by pressing the torchtrigger. Releasing the torch trigger during gas pre-flowactivates the slope-up period. If the torch trigger isreleased during the slope-up period welding continueswith the adjusted welding current. In order to stop thewelding process the trigger must be pressed againafter which the slope-down period begins. The slope-down period can be stopped by releasing the trigger.

Set weldingcurrent

slope-up slope-down

trig down ( ) / up ( )

time

Amp

SpotThe welding process begins by pressing the torchtrigger. Welding stops automatically, depending on thetime set in spot time.

Amp setting functionThe keypad is used to select

the method by which the required welding current shallbe established. This adjustment method cannot bechanged during the welding process.

Internal adjustmentThe control knob positioned below the digital

display is used to set the current.

External adjustmentCurrent setting to be by means of a Migatronic

remote control unit. The remote control unit isconnected to a plug positioned on the rear of themachine (not standard equipment).

Torch adjustmentCurrent setting to be by means of the current

control knob located in the handle of a Migatronicdialog torch, if a dialog torch is used. The maximumcurrent is set with the control knob on the front panel.The torch control is used to reduce the current fromthe maximum set current to the minimum current.

Ignition of TIG weldingIt is possible to choose be-

tween two different methods of ignition for TIGwelding: High-frequency (HF) and LIFTIG ignition. Themethod of ignition cannot be changed during thewelding process.

Two-strokeThis symbol means contact-free striking. The

arc is established in the following way:1) The torch is placed so that the Tungsten electrode

is quite close to the welding spot (1 or 2 mm).2) The torch trigger is activated, and the high voltage

generator of the machine will produce a voltageimpulse that ignites the arc. The welding processhas started. The welding process will stop whenthe torch trigger is deactivated. The arc willextinguish after the period of slope-down time. Thetorch is held at the welding spot until after theperiod of gas post-flow time in order to protect thewelding spot against oxidation.

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Four-strokeThis symbol means contact-free striking. The

arc is established in the following way:1) The torch is placed so that the Tungsten electrode

is quite close to the welding spot (1 or 2 mm).2) The torch trigger is activated, and the high voltage

generator of the machine will produce a voltageimpulse that ignites the arc.The torch trigger is deactivated. The weldingprocess will stop when the torch trigger is re-activated. The arc will extinguish after the period ofslope-down time. The torch is held at the weldingspot until after the period of gas post-flow time inorder to protect the welding spot against oxidation.

Two-strokeThis symbol means LIFTIG ignition. The arc

is established in the following way:1) The torch is placed so that the Tungsten electrode

has contact with the welding spot.2) The torch trigger must be kept pressed down.3) The arc is established by lifting the torch, and the

welding process has started. In order to stop thewelding process, the torch trigger is deactivated.The arc will extinguish after the period of slope-down time. The torch is held at the welding spotuntil after the period of gas post-flow time in orderto protect the welding spot against oxidation.

Four-strokeThis symbol means LIFTIG ignition. The arc

is established in the following way:1) The torch is placed so that the Tungsten electrode

has contact with the welding spot.2) The arc will be established when the torch trigger is

activated and the torch is lifted. In order to stop thewelding process, the torch trigger is reactivated.The arc will extinguish after the period of slope-down time. The torch is held at the welding spotuntil after the period of gas post-flow time in orderto protect the welding spot against oxidation.

Please note! Both HF as well as LIFTIG ignitioncannot be effected until post-flow is finished.

Pilot arcIn this section it is possible to

choose whether the pilot arc should be activated ornot. Connection/disconnection of this function cannotbe changed during the welding process.

The pilot arc cannot be activated

The pilot arc can be activated

Used only in the TIG welding process, a pilot arc is aweak arc which illuminates the workpiece, and therebymakes it easier to find the starting point of the actualwelding process.

The pilot arc can be ignited by briefly activating thetorch trigger (less than 0.3 seconds). If activation islonger (more than 0.3 seconds), the machine switchesautomatically to ordinary welding.Switch from pilot arc to ordinary welding by keepingthe torch trigger activated when two-times TIG-weldingor by long activation (>0.3 seconds) when four-timesTIG or spot welding. The welding process thencontinues in normal fashion.However, after slope-down the machine does notswitch directly to post-flow but to pilot arc again. It isnow possible to continue with a new welding processby a lengthy activation of the torch trigger (> 0.3seconds), or to go to standby automatically by a briefactivation (< 0.3 seconds).

The welding processfor TIG weldingThe parameters can beselected and adjustedduring the welding pro-cess.

Pre-flowPre-flow is the period of time for which gas

flows after the torch switch is pressed and before theHF arc is established, or until the torch is lifted awayfrom the workpiece in the LIFTIG process. Variable 0-10 secs.

Start AmpImmediately after the arc has been

established, the machine regulates the welding currentto the value stated in the Start Amp parameter. StartAmp is set as a percentage of the required weldingcurrent and is variable between 0-100% of the weldingcurrent with a minimum value of 5 A.

Slope-upOnce the arc has been established, the weld-

ing process enters a slope-up stage during which thewelding current is increased in linear fashion from thevalue stated in the Start Amp parameter to therequired welding current. The duration of this slope-uptime is variable 0-10 secs.

Slope-downWhen welding has stopped by activating the

trigger, the machine enters a slope-down stage.During this stage current is reduced from welding cur-rent to Stop Amp over a period of time called theslope-down time and variable 0-10 secs.

Stop AmpThe slope-down stage is completed when the

current level has fallen to the value stated in the StopAmp parameter. Stop Amp is stated as a percentageof the required welding current and is variable be-tween 0-100% of the welding current with a minimumvalue of 5 A.

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Post-flowPost-flow is the period of time for which gas

flows after the arc is extinguished and is variable 3-30secs.

Reduced currentWhen four-times welding a reduced current is

activated by pressing the trigger briefly. This reducedcurrent is set to a percentage value of the weldingcurrent and is variable between 0-100% of the weldingcurrent with a minimum value of 5 A.

Indication of a welding processDuring welding, when adjustment of current isactivated by means of the A-keypad, it is possible tosee the actual phase of the welding process.

Pulse weldingThis section contains functions forpulse welding. The section is dividedin two: the above connects or dis-connects pulse welding, the belowcontains the diffent pulse parameters.

Pulse cannot be connected or disconnected during thewelding process.

PulsePulse welding has been selected.

No pulseWelding without pulse has been selected. Thepulse parameters cannot be activated.

Pulse parametersThe pulse parameters can be both selected andchanged during pulse welding. The figure belowillustrates the meaning of the three pulse parameters.

Set weldingcurrent

Base current

pulse timepause time

time

Amp

The pulse timeReflects the time the machine is welding withthe pulse current. The pulse current is the

adjusted welding current. Time is adjustable between0.01 and 10 seconds.

Pause timeReflects the time the machine is welding withbase current. Time is adjustable between 0.01

and 10 seconds.

Base AmpIs set as a percentage value between 1 and

99% of the current level set on the display (= pulsecurrent), although this percentage cannot be less thana value that corresponds to 5 A.

Parameters for MMA weldingand TIG spot weldingParameters can be both selected

and adjusted during welding.

Arc-powerThe arc power function is used to stabilise the

arc in MMA welding. This can be achived by in-creasing welding current during the short-circuits. Theadditional current ceases when the short circuit is nolonger present.

Set weldingcurrent short-

circuit

Additional currentsupply from the arcpower function

time

Amp

Arc power can be adjusted between 0 and 150% ofthe welding current setting.

E.g. If the welding current is set to 40A and arcpower to 100% the additional current is 40 Aequals 80 A when doing arc power. If the arcpower is set to 150% the additional current is 60A equals 100 A when doing arc power.

Hot startHot start is a function that helps to establish the

arc at the beginning of MMA welding. This can beachieved by increasing welding current (when theelectrode is applied to the workpiece) in relation to theset value. This increased start amp is maintained forhalf a second, after which it decreases to the set valueof welding current.

Set weldingcurrent

Weldingstart

0,5 s

Additionalcurrent supplyfrom hot-start-function

time

Amp

The hot start value reflects the percentage value bywhich initial current is increased, and can be set be-tween 0% and 100%.

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Spot timeThe spot time in TIG is the time from the end of slopeup to beginning of slope down. Therefore, the spottime is welding with the adjusted current. The time withthe arc and torch trigger activated is the spot time plusslope up time and slope down time.

Set weldingcurrent

slope-up

spotwelding time

slope-down

time

Amp

trig down ( ) / up ( )

If spot time is changed during welding, this change willnot be carried into effect until next welding process. Itis possible to interrupt the spot welding time by re-leasing the torch trigger.

AC-weldingThis panel is divided into twosections, with the function currenttype at the top, and the setting ofconditions for special AC-functions atthe bottom.

Current typeIt is possible to select either AC(alternating current) or DC (direct

current). In the TIG-welding process, AC is used forthe welding of aluminium and its alloys, while DC isused for the welding of other materials.When TIG welding aluminium or its alloys the positivepart of the AC-wave removes the oxide film coveringthe surface of the workpiece, and the negative part ofthe wave melts the material.

AC-frequencyThe AC frequency can be adjusted from 1 to 300 Hzfor TIG welding and from 1 to 100 Hz for MMA-welding. A low frequency during TIG welding in-creases the tendency for the formation of a large ballat the end of the tungsten electrode. This tendency willbe reduced by increasing the frequency.Note 1: The AC frequency and welding current cannot be

adjusted to maximum simultaneously during TIGwelding - see the following illustration. When thelimit is reached by adjusting the AC-frequency, theA-lamp will illuminate in "units for parameter" andthe machine will reduce the AC frequency auto-matically.

Note 2: If the frequency limit is exceeded by adjustment ofthe welding current the AC frequency will bereduced automatically (the indicator for ACfrequency flashes on and off for 5 sec.).

Note 3: If the pulse function is used during AC-welding theAC frequency can be reduced in proportion to thepulse times. If the AC frequency is to low theindicators for pulse times will flash on and off for 5seconds.

Note 4: Pulse adjustment error: If the pulse function is usedduring AC-welding an automatic adjustment of thepulse setting may occur. The indicators for pulsetimes will then flash on and off for 5 seconds. Thepulse times change automatically so the pulse timeand base time will be 0.03 seconds.

Electrode preheating (TIG)On ignition of the AC TIG pilot arc the tungstenelectrode is preheated by a direct current with positivepolarity. Preheating of an electrode is necessarybefore starting the AC welding process. The length ofthe preheat period depends on both the diameter ofthe electrode and the angle of the point of theelectrode, as well as the size of the ball at the end ofthe electrode.Adjustment is possible from -9 to +9, with -9 being theminimum and +9 being the maximum preheat periods.If the period is too short the pilot arc will extinguishshortly after ignition. The size of the ball at the end ofthe electrode will increase if the pre-heat period is toolong.

AC-t-balance, based on time (TIG)Adjustment of the refinement function during the

AC TIG welding of aluminium and its alloys. Thefunction is a balance based on time between thepositive and negative halfperiod.Adjustment is possible between 1 and 100 per cent asthe statement in per cent is based on the negative partof the period time. Adjustment continues until a suit-able refinement zone is established around the moltenpool. When MMA welding the balance can be lockedat 50 per cent which means that further regulation isimpossible.

AC-I-balance, based on current intensity(TIG)

The purpose of the function is also adjustment of therefinement zone during AC TIG welding.

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100% 150% 50%

However, this balance is based on the current intensityof the positive period proportional to the currentintensity of the negative period. A reduction of thepositive refinement current may have the effect thatdwell time of the tungsten electrode improves.

TIG-DCIt is also possible to weld in DC TIG with unalloyedtungsten electrodes (green marking). Current is set toAC and both AC-t-balance and AC-I-balance are set at100 per cent. The machine will then establish the pilotarc by using the preheating function. After finishing thepreheating period the welding current will be returnedto negative polarity.

Fixed functionsThe functions below are fixed and cannot beconnected and disconnected from the display:

Anti-freezeThe anti-freeze-function is always on. During MMAand TIG welding the electrode sometimes sticks ontothe workpiece. The machine will register that theelectrode has stuck onto the workpiece, and will thenreduce the welding current so that the area of theworkpiece which has melted will harden, making itpossible to break off the electrode. Welding can thencontinue in the usual way.

Torch coolingThe machine will automatically start cooling whenestablishing the arc if the machine has been mountedwith a cooling module and a Migatronic water-cooledtorch. Cooling continues until 2½ min. after the weldingprocess has stopped.

Ignition of the arc in AC/TIG weldingIt can be advantage to use reduced start current (e.g.25%) and slope up (e.g. 0.1 sec.) during ignition of thearc in AC/TIG welding as wolfram from the electrodepin can be avoided on the work piece. This method isespecially recommendable during welding with largecurrents.

FAULT IDENTIFICATIONOverheating errorWelding is interrupted due to overheating if the

machine is used beyound the specificationsmentioned in chapter "Technical Data". The machinemust remain turned on and connected to the mainssupply as the fan continues until the machine hasbeen sufficiently cooled. Thereafter, the machine isautomatically switched in.An overheating error is more oftenly seen if themachine is used in surroundings with temperaturesabove 40oC. It is not recommendable to place themachine in direct sun light as this increases thepossibility of an overheating of the machine.

Mains errorThe mains error arises if the mains voltage is

too high or low.Please make sure that the mains plug is correctlymounted and that all fuses are intact. Moreover,please control that the mains voltage does not exceedthe technical specifications and that there are no short-term voltage drops or voltage peaks.

Torch cooling errorThis error can be seen by the text "Etc" in the machinedisplay. Turn off the machine if the cooling water doesnot flow in the water-cooled torch. Make sure that allhoses have a free passage, see chapter"maintenance". Turn on the machine again when afree passage has been established. Welding can thenbe continued.

Other errors shown in the displayIf other errors arise than those decribed above, pleasecontact the Migatronic service department.

22

TECHNICAL DATANAVIGATOR NAVIGATOR NAVIGATOR2500 AC/DC 3000 DC 3000 AC/DC

Power source:Mains voltage 3x400 V ±15% 3x400 V ±15% 3x400 V ±15%

Fuse 16 A 16 A 16 A

Consumption max.

Efficiency

Permitted load- 25% duty cycle 250 A / 32 V 300 A / 32 V 300 A / 32 V- 60% duty cycle 220 A / 30 V 240 A / 29.6 V 240 A / 29.6 V- 100% duty cycle 170 A / 27.6 V 190 A / 27.6 V 190 A / 27.6 V

Max. arc voltage 38 V / 250 A 38 V / 250 A 38 V / 250 A

Open circuit voltage 95 V 95 V 95 V

Current range AC 5 – 250 A 5 – 300 ACurrent range DC 5 – 250 A 5 – 300 A 5 – 300 A

1Application class S S S2Protection class (IEC 529) IP 23 IP 23 IP 23

Standards EN/IEC60974-1 EN/IEC60974-1 ENIEC60974-1EN/IEC60974-10 EN/IEC60974-10 EN/IEC60974-10

Dimensions (H- W-L) (mm) 563x300x698 563x300x698 563x300x698

Weight with torch cooling 37 kg 39 kg 43 kgWeight without torch cooling 31 kg 33 kg 37 kg

Torch cooling:Cooling capacity 0.71 kW 0.71 kW 0.71 kW

Tank capacity 4 liters 4 liters 4 liters

Functions: Process NAVIGATOR2500 / 3000

Arc power Electrode 0-150 %, max. 250/300 A

Hot-start Electrode 0-100 %, max. 250/300 A

Anti-freeze TIG/Electrode always on

Pilot arc TIG 5 %, min. 5 A

Start AMP TIG 0-100 %, min. 5 A

Stop AMP TIG 0-100 %, min. 5 A

Slope up TIG 0-10 secs

Slope down TIG 0-10 secs

Gas pre-flow TIG 0-10 secs

Gas post-flow TIG 3-30 secs

Spot welding time TIG 0.1-50 secs

Pulse time TIG/Electrode 0.01-10 secs

Pause time TIG/Electrode 0.01-10 secs

Base Amp TIG/Electrode 1-99 %, min. 5 A

Reduced current TIG 0-100 %, min. 5 A

AC-balance 1-100 % (only AC) 1-100 % (only AC)

AC-balance, Ampere 1-200 % (only AC) 1-200 % (only AC)

AC-frequency 1-300 HZ (only AC) 1-300 HZ (only AC)

TIG-ignition TIG HF / LIFTIG

Triggerfunction TIG 2/4-stroke

Setting of welding jobs TIG/Electrode 10

1 S The machine meets the standards which are demanded of machines

working in areas where there is an increased risk of electric shock2 Equipment marked IP23 is designed for indoor and outdoor

applications

MAINTENANCEInsufficient maintenance may result in reducedoperational reliability and in lapse of guarantee.The NAVIGATOR 2500/3000 welding machines re-quire virtually no maintenance. However, exposure toextremely dusty, damp or corrosive air is damaging towelding machines.

Periodical maintenanceIn order to prevent problems arising, the followingprocedure should be observed at least once a year oras required.- disconnect the machine from the mains supply and

wait 2 minutes before removing the front panels.- clean the fan blades and the components in the

cooling pipe with clean, dry, compressed air.- drain the cooling liquid out of the cooling module

and welding hoses. Remove dirt and flush with purewater in the tank and cooling hoses. Fill up with newcooling liquid. The machine is delivered with acooling liquid of type propylene glycol in the ratio 1:3which provides an anti-freeze solution up to -10oC.

WARRANTY REGULATIONSAll MIGATRONIC machines carry a twelve monthguarantee against hidden defects. Such defects must benotified no later than two months after it has been noticed.The warranty runs for twelve months after invoicing toend customer.The warranty becomes void by faults that can beattributed to incorrect installation, pests, transportdamages, water- and fire damages, strokes of lightning,use in connection with a synchronous generator and useunder abnormal conditions, which lies beyond the productspecification.

Lack of maintenanceThere is a lapse of warranty if the product is not properlymaintained. E.g. if the product is dirty to such a degreethat cooling is hindered. The warranty does not coverdamages, which can be traced back to unauthorised andincorrect repairs of the product.

Wear partsThe warranty does not cover wear parts (welding hoses,welding cables and wire drive rolls)

Resulting damagesUse of the product must stop immediately after acknow-ledgement of a defect in order to avoid further damage ofthe product. The warranty does not cover resultingdamages due to use of the product after acknowledge-ment of a defect. Moreover, the warranty does not coverresulting damages on other items due to product defect.