ESAB MLC 302 Instruction manual

MLC 302

Elektrodmatarenhet
Elektrodefremføringsenhed
Elektrodematerenhet
Langansyöttöyksikkö
Wire feed unit
Drahtelektrodenvorschubgerät
Dévidoir
Draadaanvoereenheid
Unidad alimentadora de electrodo
Alimentatore di filo
Unidade de alimentação de electrodos

МпнЬдб фспцпдьфзузт злекфспдЯпх

Bruksanvisning
Brugsanvisning
Bruksanvisning
Kätyttöohjeet
Instruction manual
Betriebsanweisung

Manual d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções

ПузгЯет чсЮуещт

455 660--001 95--09

Valid from Machine no 519 XXX--XXXX

SVENSKA 3.........................................

DANSK 9............................................

NORSK 15............................................

SUOMI 21............................................

ENGLISH 27..........................................

DEUTSCH 33.........................................

FRANÇAIS 39.........................................

NEDERLANDS 46.....................................

ESPAÑOL 52.........................................

ITALIANO 58..........................................

PORTUGUÊS 64......................................

ЕЛЛНЙКБ 70..........................................

Rätt till ändring av specifikationer utan avisering förbehålles.
Ret til ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner uten varsel forbeholdes.
Oikeudet muutoksiin pidätetään.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Ci riserviamo il diritto di variare le specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.

ДйбфзсеЯфбй фп дйкбЯщмб фспрпрпЯзузт рспдйбгсбцюн ЧщсЯт рспейдпрпЯзуз.

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

SVENSKA

Esab Welding Equipment AB, 695 81 Laxå, Sverige, försäkrar under eget ansvar att
elektrodmatarenhet MLC 302 med serienummer 519 är i överensstämmelse med
villkoren i direktiv 89/392/EEC, med tillägg 93/68/EEC.

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OVERENSSTEMMELSEERKLAERING

DANSK

Esab Welding Equipment AB, 695 81 Laxå, Sverige garanterer under eget ansvar, at
elektrodefremføringsenhed MLC 302 med serienummer 519 er i overensstemmelse
med betingelserne i direktiv 89/392/EEC, med tillægg 93/68/EEC.

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FORSIKRING OM OVERENSSTEMMELSE

NORSK

Esab Welding Equipment AB, 695 81 Laxå, Sweden, forsikrer på eget ansvar at
elektrodematerenhet MLC 302 med serienummer 519 er i overensstemmelse med
bestemmelsene i direktiv 89/392/EØF, med tillegg 93/68/EØF.

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VAATIMUSTENMUKAISUUSVAKUUTUS

SUOMI

Esab Welding Equipment AB, 695 81 Laxå, Sweden, vakuuttaa omalla vastuullaan,
että langansyöttöyksikkö MLC 302 sarjanumero 519 vaatimukset direktiivin
89/392/EEC, ja sen lisäyksen 93/68/EEC mukaisesti.

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DECLARATION OF CONFORMITY

ENGLISH

Esab Welding Equipment AB, of 695 81 Laxå, Sweden, gives its unreserved guaran­tee that Wire feed unit MLC 302 having serial number 519 is in accordance with the
requirements of directive 89/392/EEC, and addendum 93/68/EEC.

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KONFORMITÄTSERKLÄRUNG

DEUTSCH

Esab Welding Equipment AB, 695 81 Laxå Schweden, versichert hiermit auf eigene
Verantwortung, daß die Drahtelektrodenvorschubgerät MLC 302 mit Serien--Nr. 519
gemäß den Bedingungen der Richtlinien 89/392/EEC, mit der Ergänzung 93/68/EEC
in Übereinstimmung steht.

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CERTIFICAT DE CONFORMITÉ

FRANÇAIS

Esab Welding Equipment AB, 695 81 Laxå Suède, certifie sous sa propre responsa­bilité que la dévidoir MLC 302 portant le numéro de serié 519 conformément aux di­rectives 89/392/EEC, avec annexe 93/68/EEC.

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OVEREENSKOMSTIGHEIDSVERKLARING

NEDERLANDS

Esab Welding Equipment AB, 695 81 Laxå Sweden, verklaart op eigen verantwoor­delijkheid dat draadaanvoereenheid MLC 302 met serienummer 519 volgens richtlijn
89/392/EEG, met toevoeging 93/68/EEG.

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1

DECLARACIÓN DE CONFORMIDAD

ESPAÑOL

Esab Welding Equipment AB, 695 81 Laxå, Suecia, declara, asumiendo toda re­sponsabilidad, que unidad alimentadora de electrodo MLC 302 con el número de
serie 519 según los requisitos de la directiva 89/392/EEC, con el suplemento
93/68/EEC.

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DICHIARAZIONE DI CONFORMITA

ITALIANO

Esab Welding Equipment AB, 695 81 Laxå Swezia, dichiara sotto la propria respon­sabilità che il alimentatore di filo MLC 302 numero di serie 519 ai sensi dei requisiti
previsti dalla direttiva 89/392/CEE, e successive integrazioni nella direttiva
93/68/CEE.

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DECLARAÇÃO DE CONFORMIDADE

PORTUGUÊS

Esab Welding Equipment AB, 695 81 Laxå Suécia, certifica, sob a sua própria re­sponsabilidade que, a unidade de alimentação de fio MLC 302 número de série 519
está fabricada em conformidade com os requisitos constantes na directiva
89/392/EEC, e com o suplemento 93/68/EEC.

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ВЕВБЙЩУЗ УШМЦЩНЙБУ

Ç Esab Welding Equipment AB, 695 81 Laxå Sweden, вевбйюней ме дйкЮ фзт ехиэнз
oфй з рзгЮ фсцпдуфйкь MEK 2 брь¯фпн бсйимь уейсЬт 510 всЯукефбй уе ухмцщнЯб
ме фп пфбнфбсф ЕН 60974 --1 уэмцщнб ме фпх ьспхт фзт пдзгЯбт 73/23/ЕЕC кбй
фзн рспуиЮкз 93/68/ЕЕC.

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Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81176 Fax: + 46 584 12336

2

ENGLISH

INTRODUCTION 28.....................................................

TECHNICAL DESCRIPTION 29...........................................

Wire feed unit MLC 302 29..........................................................

Technical data 30..................................................................

INSTALLATION 31......................................................

Connecting the welding hose 31......................................................

Connecting the welding current 31....................................................

Connecting the compressed air 31....................................................

NOTE! 31.........................................................................

Connecting the shielding gas 31......................................................

MAINTENANCE 32......................................................

Replacing the wire 32...............................................................

Cleaning 32.......................................................................

Ordering spare parts 32.............................................................

DIAGRAM 77............................................................

SPARE PARTS LIST 78...................................................

TOCe

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INTRODUCTION

INTRODUCTION

The MLC 302 is a component of the A9 semi--automatic series ”push--pull”--system.
This means that a motor driven wire feed unit pushes the wire through the welding
hose to the gun, and from there the compressed air motor in the welding gun pulls
the wire out to the contact tip. The push--pull system ensures smooth, problem--free
wire feed, which is especially important when welding soft consumables such as
aluminium and thin wires. It also permits the use of welding hoses up to 16 m in
length. It simplifies the work of the welder considerably and extends his working
radius, since the wire feed unit can also be separated from the power source.

Besides the drive motor, the wire feed unit comprises a connecting block for the
welding hose, brake hub for wire reels up to 300 mm in diameter, plus control
devices, i.e. solenoid valve for shielding gas, compressed air valve with filter
regulator and current relay.

The wire feed unit can be placed in a variety of positions. If equipped with a
counterbalance and/or turntable the MLC 302 can be made to swivel over the guide
journal on the power source. It can be fitted with a suspension device and
suspended over the work place. It can also be fitted with wheels (carriage) for
free--standing use and easy positioning on the floor or work bench.

MLC 302 is available in a version for connection to 42 V, 50/60 Hz.

WARNING

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU­TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can kill

S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and

the general area.

ARC RAYS -- Can injure eyes and burn skin.

S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearing

S Protect your ears. Use ear defenders or other hearing protection.
S Warn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

bm15d12e

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TECHNICAL DESCRIPTION

TECHNICAL DESCRIPTION

The MLC’s aluminium casing is divided vertically into two sections. One section,
which is protected by a screwed panel, contains the electrical and pneumatic
regulating equipment. The other section is covered at the top and side by a hinged
panel. In the closed position this panel is secured to the bottom panel by a snap lock.
This section contains the hub for the wire reel, the wire feed mechanism with electric
motor and connecting block for welding hose.
The rear panel has a grommet to allow the passage of the welding cable out of the
power source.

MLC 302 is fitted with a filter regulator. This drains automatically when the
compressed a ir system is switched off. The pressure is permanently set at 500 kPa
(5 kg/cm2).

Wire feed unit MLC 302

The motor driven wire feed unit is mounted on the output shaft of the electric motor
and comprises a driven feed roller and freewheeling pressure roller. The pressure
roller, which consists of a simple ball bearing, is mounted on a camshaft, which runs
in a needle bearing housed in the casing. Pressure is exerted on the wire by means
of torque applied to the camshaft by an adjustable spring mechanism.

The design of the wire feed unit insulates the welding wire from the outer casing.
The inlet and outlet nozzles are made of hardened steel. When welding with Æ1.6
mm wire the outlet nozzle must be removed from the wire feed unit. On the front
panel is a remote socket (M 26) to allow remote control of voltage. This requires a
thyristor regulated power source, e.g. LAH 315/500 or LUA 400.

WARNING!

Rotating parts can cause injury, take great care.

IMPORTANT!

To prevent the reel sliding off the hub: Lock the reel in place
by turning the red knob as shown on the warning label atta­ched next to the hub.

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TECHNICAL DESCRIPTION

Technical data

Connection data

Continuous A weighted
noise pressure level 58 dB

Voltage 42 V, 50/60 Hz
Power rating 85 VA
Control cable Conductor, type RDO 6x1 mm
Gas connection Hose nipple for Æ 6 mm hose
Air connection Coupling för 1/4” hose
Air pressure Min. 500 kPa (5 kg/cm2)
Welding current Max. 400 A at 60 % duty cycle
Wire feed speed Max. 15 m/min. Adjusted at welding gun

Wire diameter Æ 0.6--1.6 mm
Inlet nozzle Bore Æ 2.7 mm
Outlet nozzle Bore Æ 1.5 mm

Outlet nozzle must be removed with Æ 1.6 mm wire

Brake hub

intended for wire reel with:
External diameter Æ 300 mm
Hub diameter Æ 51.1 mm
Hub length 100 mm

2

Dimensions

Lxbxh 577x279x465 mm
Weight 18 kg

bm15d12e

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INSTALLATION

INSTALLATION

Connecting the welding hose

1. Open the side of the wire feed unit that contains the wire feed mechanism. Undo
the locking screw on the connecting block.

2. Choose the appropriate inlet nozzle for the wire being used and push it securely
into the welding hose.

3. Connect the welding hose to the wire feed unit and tighten the locking screw on
the connecting block.

4. Remove the plastic cover from the gun housing, undo the locking screw and
push in the other end of the welding hose. Then tighten the locking screw.

5. Check that the welding hose connections are correctly positioned and that the
locking screws have been securely tightened. Refit the plastic cover.

Connecting the welding current

Connect the welding cable from the positive socket on the power supply to the
current terminal on the connecting block.

Connecting the compressed air

Remove the panel, which is secured to the casing by four screws. Pull the supply air
hose through the hole in the opposite side of the casing (next to the control cable)
and connect the compressed air hose directly to the nipple on the filter regulator.
Tighten the compressed air hose.

NOTE!

If the wire feed unit is suspended the filter regulator must be set in the vertical
position. This prevents any water remaining in the compressed air system from
reaching the welding gun and causing operating problems.
Rotate the filter regulator anticlockwise so that it is directly opposite the hole in the
casing intended for this purpose. Then tighten the filter regulator.

Connecting the shielding gas

Connect the shielding gas directly to the nipple on the solenoid valve.

WARNING

This product is intended for industrial use. In a domestic environment this product
may cause radio interference. It is the users responsibility to take adequate pre­cautions.

-- 3 1 --bm15d12e

MAINTENANCE

MAINTENANCE

Replacing the wire

The wire conduit is made of plastic and can be damaged by sharp objects. Remove
any burrs or sharp edges from the tip of the wire using a file, before feeding the new
wire into the wire conduit.

1. Release the pressure roller springs.

2. Withdraw any remaining wire from the conduit. Remove the wire reel.

3. Fit the new wire reel.

4. Straighten out the first 5--10 cm of the wire and file off any sharp edges from the
tip of the wire.

5. Make sure the correct size inlet nozzle is fitted to the welding hose.

6. Guide the wire into the wire feed unit. Make sure it passes through the grooves
in the feed rollers, into the outlet nozzle and then into the inlet nozzle of the wel­ding hose. If welding with Æ 1,6 mm wire the outlet nozzle must first be removed.

7. Re--tension the pressure roller springs.

8. Fit the correct contact tip to the welding gun.

9. Switch on the power source, press the gun trigger and allow the wire to advance
through the welding hose and out of the contact tip.

Cleaning

When necessary clean the wire feed mechanism in the wire feed unit and the wire
conduit in the welding hose using compressed air. Clean the grooves in the feed
roller and pressure roller.
You should also clean the inlet and outlet nozzles of the wire feed mechanism.
Dismantle as follows:

1. Undo the screw on the connecting block using an Allen key, then remove the
welding hose.

2. Undo the two stop screws that hold the inlet and outlet nozzles in place and re­move them.

3. Refit the nozzles after cleaning.

Ordering spare parts

When ordering please state the machine model, serial number, part name and part
number. This simplifies dispatch and ensures correct delivery.

bm15d12e

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