Page 1
910.1053.1-12
Operation Manual
MIG/MAG Welding System
M-Series
Page 2
2
12
4
5
7
6
8
3
9
6
1 Pressure reducer
2 Gas cylinder*
3 Torch
4 Tray area
5 Handle
6 Connections
7 Operation panel
8 Transport wheels
9 Ground clamp
*) accessory
Depicted or described accessories are partly
not included at delivery.
Page 3
3
Use and maintenance of welding and cutti ng
machines can be dangerous. Please draw
user´s attention to follow the safety precau
tions to avoid injuries. Welding a nd cutting
machines must be used appropriate and
only by specialist staff. Please inform yourself constantly about the valid safety precautions and regulations of accident prevention
by working with this machine*.
Remove all flammable material from the welding area for fire prevention before welding.
Do not weld at containers which were filled up
before with flammable materials (fuel).
All inflammable material in the welding area
which could be inflamed by sparks must be re
moved.
Check after welding the place conforming UVV.
Do not expose the unit to rain, steam and do not
spray water in it.
Do not weld without protection shield. Keep attention to protect other persons in the welding
area against arc-rays.
Please use absorbers or other systems to absorb the gases.
It is not possible to absorb all the gases correctly please use a breathing apparatus.
Stop operation immediately at a defect or
damaging of the mains cable. Do not touch
the cable. Unplug the unit before each ser
vice or repair. Do not use the machine if the
mainscable is defect.
Place an extinguisher near the welding area.
Check the welding area against fire after wel-
ding.
Never try to repair a defect pressure reducer.
Replace the defect one.
Please transport and fix the welding unit only
on firm and even underground.
The max.allowable inclination angle for transport and fixind is 10°.
Seviceand repair work is permitted only to a trained elec-
trical specialist.
Keep attention to connect the ground cable near the wel-
ding location. Welding current through chains, ball-bearing
or steel-cables may destruct or melt it.
Secure yourself and the unit at higher or inclinational pla-
ces.
The machine may only be connected to a properly groun-
ded mains supply.
(three-phase four-wire system with grounded neutral conductor or single phase-three-wire-system with grounded
neutral conductor)
Socket and extension cable must have a functional protective conductor.
Wear correct protective clothing, gloves and leather apron.
Protect the welding area with curtains or mobile walls
against rays.
Do not thaw frozen waterpipes or conductions with this
unit.
In high electrical risk areas (in confined spaces) it is only
allowed to use machines with
-sign.
Switch off the machine at breaks and close the valve of the
gas cylinder.
Secure the gas cylinder with a chain against falling over.
Please take off the gas cylinder from the machine for trans-
portation.
Disconnect the plug from the mains before changing the
welding area or repairs at the machine.
*) available from Carl Heymanns-Verlag,
Luxemburger Str. 449, 50939 Cologne.
Please follow the current safety regulations corresponding to
your country..
The welding equipment shall be transportet
only driving!
To lift up the welding equipment with
chains or ropes is not permitted.
Take off the gas bottle from the equipment
before the transport.
This unit is for welding of steel, aluminium and their alloys as
well as for brazing with CuSi wires for commercial as well as
for industrial use.
This unit is protected electronically against overloading.
However the stepswitch should be not used under load.
Connect the workpiece with the groundcable to the machine.
Remove welding spatter from the inside of the gas nozzle with
a special pair of pliers. Spray with anti spatter spray inside the
gas nozzle to avoid adherence of spatters. Spray sloping to
avoid the obstruction of the gasoutlet.
The sound level of the unit is smaller as 70 db(A) measured
at standard load conforming EN 60974 at the max. workpoint.
1 Safety precautions
2 Transportation
3 General regulation of use
4 Unit protection
5 Noise emission
S
Page 4
4
This product is manufactured conform to the current EMC
standard. Please notice following items:
The unit is for welding under commercial or industrial con-
ditions (CISPR 11 class A). The use in other surroundings
(for example in residential areas) may disturb other electric
devices.
During welding electromagnetic problems can be caused
at:
– Mainscables, controlcables, connections for telecom-
munication
– TV/Radio
– Computer and other similar devices
– Protection devises as for example alarm systems
– Pacemakers and hearing aids
– Devices for measure and calibrate
– Devices with less protection against disturbances
If other devices are disturbed it may be necessary to pro-
tect additionally.
The affected area can be bigger than your premises/pro-
perty depends of the building etc.
Please use the unit conform to the instructions of the manufacturer. The user is responsible for installation and use of the
machine. Furthermore the user is responsible to eliminate the
disturbances caused by electromagnetic fields.
6 Electromagnetic compatibility (EMC)
7 Technical data
type M 2020 M 2040 M 2060
M 2070
CuSi
M 2080 M 2090 M 2095
welding range A/V 30-140/
15,5-21
25-170/
15,2-22,5
25-210/
15,2-24,5
15-150 /
14,8-21,5
30-230/
15,5-25,5
30-290/
15,5-28,5
25-350/
15,3-31,5
no load voltage
(max.)
V 36,8 34,9 36,9 27,5 32,6 37,2 42
voltage adjustment Stufen 6 6 6 7 7 12 24
duty cycle at max.
power (25
°C/
40
°C)
% 25/15 25/15 25/15 -/40 30/20 30/20 30/20
Welding current at
100 % duty cycle
(25 °C/40 °C)
A 70/55 90/70 105/85 -/100 140/115 160/135 185/160
weldable wire steel mm Ø 0,6-0,8 0,6-0,8 0,6-1,0 0,6-0,8 0,6-1,0 0,6-1,2 0,6-1,6
weldable wires:
CuSi3
mm Ø - - - 0,8-1,0 - - -
weldable wire alu mm Ø 1,0 1,0 1,0-1,2 1 1,0-1,2 1,0-1,2 1,0-1,6
wire-feed speed m/min 1-23 1-23 1-23 1 - 23 1-23 1-25 1-25
mains voltage V 1~ 230 1~ 230/
2~ 400
1~ 230/
2~ 400
3~ 400 3~ 400 3~ 400 3~ 400
mains frequency Hz 50/60 50/60 50/60 50/60 50/60 50/60 50/60
mains fuse tr/C 16 16 16 10 16 16 25
mains current input
(max.)
A 16,3 16,4 21,6 6,5 9,8 15,6 21,5
input power (max.) kVA 3,7 5,2 6,4 4,5 6,8 10,8 14,9
power factor cos ϕ 0,85/140 A 0,84/170 A 0,89/210 A 0,89/150 A 0,89/230 A 0,89/290 A 0,89/350 A
cooling method F F F F F F F
insulation class F F F F F F F
protection class
(IEC
529)
IP 23 IP 23 IP 23 IP 23 IP 23 IP 23 IP 23
dimensions,
approx. (LxWxH)
mm
870x390x610 870x390x610 870x390x610 870x390x610 870x390x610 870x390x610 870x390x610
weight kg 47 51 55 66 57 67 94
torch type ML1500 ML1500 ML1500 ML 1500
CuSi
ML2500 ML2500 ML3600
standard EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1
order number 2 rolls 202.2020.1 202.2040.1 202.2060.1 202.2070.1 202.2080.1 - order number 4 rolls - - 202.2061.4 202.2071.4 202.2081.4 202.2090.1 202.2095.1
Page 5
5
Torch Connection
Plug in the centralplug 11 of the torch 3 into the central socket
10.
How to connect the ground cable
Connect the ground cable 13 at the groundconnection 12 and
fasten it turning to right and connect the ground clamp 9 to the
workpiece or at the welding table.
How to connect the ground clamp
Fasten the ground clamp 9 near the welding location, this
avoids that the current will flow trough machineparts or con
-
trols.
Please keep attention that the connections between ground
clamp and workpiece is constant.
Do not place the ground clamp on the welding machine or
gas cylinder, otherwise welding current is conducted via
the protective conductors and will destroy them.
Connect the ground clamp tightly to the welding bench or
to the workpiece.
How to connect at the mains.
Plug in the plug into the mains socket. The fusing should be
corresponding to the technical data.
How to insert the wirespool
Open the lid at the machine and screw off the nut 17 from the
wire-coil pick-up 15.
Put on the wire coil at the wire-coil pick-up and pay attention
that the tappet is well insert at the coil 14.
By use of small wire coils please use the adapter (art.no.
620.9650.0).
Adjust the brake 16 by releasing the torch button the wire coil
do not continue to turn.
Insert of the wire electrode
Screw out the contact tip at the torch 3.
Open the lid at the machine.
The diameter of the wire should correspond to the diameter of
the feeding rolls. This is readable on the front at th e built in
feeding roll 19.
Lift the lever 20 and thread in the wire electrode trough the inlet nozzle 21 and the central connection 10.
Close the lever 18 and fasten it with the sweep levers 20.
8 Before operation
10
11
12
13
2
1
1
L1(R)
L
2
(S)
L
3
(T)
N(MP)
PE
1
1
2
14
15
16
17
1
2
3
19
18
20
10
21
22
Double-roller feed
Quadruple-roller feed
22
21
20
18 18
20
19
10
Page 6
6
Switch on machine at main switch 34, stretch torch cable and
press buttons 22 on operating panel. Adjust the pressure at
the modulation screws 20 that the wire-feed rolls 19 even still
are turning by holding the wire coil. The wire should not be
clamped or deformed.
Hold down button 22 until wire projects about 20 mm from
torch neck.
Screw in the contact tip corresponding to the wirediame ter
into the torch 3 and cut off the sticked out wire end.
How to connect the gas cylinder
Before opening the bottle the adjustment
screw 28 at the housing must be relieved, it
means, turned to the left, otherwise the
pressure-reducing vale could be damaged.
Put the gas cylinder 2 on the provided place at the back of the
machine and protect against falling by fastening the chain 27.
Open the gas valve 26 several times to blow out possible dirt
particles.
Turn the adjustment screw 28 of the pressure reducer 1 completely to the left.
Connect the pressure reducer 1 at the gas cylinder 2.
Connect the gas hose 23 at the pressure reducer. Open the
gascylinder and adjust the gas flow at the set screw 28 of the
pressure reducer while pressing the torch button.
The quantity will be shown at the flowmeter 24. This should
be approx. wire diameter x 10 l/min. The content of the cylin
-
der is shown by the contentmanometer 25.
How to modify the machine for aluminium
welding
Change the wire roll to a aluminium wire roll.
Change the steel-torch against an aluminiumtorch or resp.
change the wire liner against a teflon liner.
Remove the capillary tube 33 at the central connection.
Cut the teflon liner close to the end of the wire-feeding roll and
pull the brasstube over the teflon liner with the corresponding
length for stabilising it.
Fasten the torch and thread in the wire electrode.
)
The art.no. of the parts depends on the torch and wirediameter. Please see at the torch spare list.
11 centralconnection
29 nipple for 4.0 mm and 4.7 external diameter
30 o-ring 3.5x1.5 mm to prevent gas outlet
31 nut
32 teflon and plastic liner
33 sustainpipe for teflon and plastic liner with 4 mm exter-
nal diameter it substitute the capillary pipe in the central
connection.
At 4.7 mm no sustainpipe is required.
19 wire-feed roll
5
4
18
20
22
Double-roller feed
Quadruple-roller feed
22
20
18
20
18
19
p p p
correct contact
pressure
too high
wrong wire-
feed roller
26
2
27
1
23
25
24
28
11 29 30 31 32 33 19
Page 7
7
The operational concept of the M-series units is very simple:
– The wire feed automatically adjusts to the set welding
voltage.
– The wire feed can be corrected manually.
Operating panel
Main switch/M 2095: coarse Voltage-range
switch
Switch on the unit with the main switch/coarse voltage-range
switch 34 and select the required mains voltage/coarse volt
-
age range:
400 V (only with the M 2040, M 2060, M 2070, M 2080)
Operation via 400 V three-phase system.
230 V (only with the M 2020, M 2040, M 2060)
Operation via 230 V alternating current system. Use
the adapter cable included in the delivery (only with
M 2040, M 2060) for connection to the alternating current system).
0-1 (only with the M 2070, M 2090)
Operation via 400 V three-phase system.
0-1-2 (only with the M 2095)
Operation via 400 V three-phase system.
1: Low welding performance
2: High welding performance
The green mains control lamp 40 lights up.
Mode selector switch
Select the required welding mode with the mode selector
switch 36:
2-Stroke welding
Hold the torch switch pressed: The gas valve is
opened. The wire feed speed is controlled automati
-
cally, the arc is ignited.
Release the torch switch: The wire feed is stopped,
the automatically controlled burn-up period runs off.
The wire burns off so that it does not adhere to the
workpiece. The arc goes out.
4-Stroke welding
Press the torch switch briefly: The gas valve is
opened. The wire feed speed is controlled automati
-
cally, the arc is ignited.
Briefly press the torch switch again: The wire feed is
stopped, the automatically controlled burn -up period
runs off. The wire burns off so that it does not adhere
to the workpiece. The arc goes out.
Spot welding
All welding spots are carried out identical.
Press the torch switch: The arc remains for the period
of the adjusted spot welding duration and then goes
out. After the arc goes out: Release the torch switch.
Step switch
The step switch 35 is used for precision tuning of the welding
performance for the electrode and the material. Never
change the switch setting during welding.
Reduce the welding voltage with the step switch 35 when undercuts are visible.
Increase the welding voltage with the step switch 35 when an
overly high welding seam is visible.
Control knob for wire-feed
The wire feed can be fine-tuned with the control knob 38. The
wire feed is automatically controlled dependent on the adjust
ment of the welding stage. Set control knob 38 at least to the
center position when welding within the step range of 1-5 in
order to ensure sufficient wire feed.
Reduce the wire feed if the wire comes out pulsating.
Increase the wire feed if the arc is too hot.
!!! CAUTION : with a correction less than -2.5 it could happen, that the wire feed motor stops running !!!
Control knob for spot welding
The spot welding time is adjusted with control knob 37.
Overload indicator
When the yellow control lamp 39 lights up upon actuation of
the torch switch, the unit is subject to overload. Allow the unit
to cool down at no-load.
9 Starting up
38
36
34
35
37
38
36
34
35
37
3940
3940
38
36
34
35
373940
Page 8
8
Principal of the MIG/MAG welding
The welding wire is fed from the wire coil to the contact tip due
to the wire-feeding rolls. The arc burns between the melting
wire electrode and the workpiece. The welding wire acts as
arc carrier and filler material. Shielding gas flows through the
gas nozzle and protects the arc against the atmospheregas.
At metal shielded gas welding both, inert and active gases are
used. The distinction is made between Metal Inert Gas (MIG)
and Metal Active Gas (MAG) welding.
Further possible classification is by the type of arc. This
means the external form of the arc, is proneness to shortcircuiting, and the way of transfer to the workpiece.
It is not possible to select the arc force to each individual
welding process. This is only limited possible for example at
the short circuiting arc.
Short-arc welding is possible with all shielded metal arc welding processes through selection of the suitable arc voltage
and the respective speed of the wire-feed.
Types of arc
Short circuit arc
This type of arc is specially suitable for thin materials and positional welding due to a relative cool welding poo l welded
with very short arc, low arc voltage and low current. The ma
terial transfer takes place within the short circuit.
This cycle is repeated again and again so the short circuit and
the arcing period is constantly alternating.
)
The transition from the short circuit to spray arc depends on the wire diameter and the gas mixture.
Transitional arc
With continuously increasing current, the limit range from
short arc to transition arc is achieved. The material transfer
takes place partly within the short circuit and partly out of it.
The transition arc is a critical current range, characterised by
intensive spattering. This range should be avoided, if possi
ble.
Long arc
Long arcs are typical at welding at the higher ampere range
under carbondioxid and gases with a high CO2 content. It is
not particularly suitable for positional welding. In this type of
arc large drops are formed which falls into the welding pool
mainly by force of gravity. Due to that short circuits occasionally occur, which by the increase of the current at the moment
of the short circuiting lead to spattering when the arc is reignit
ed.
Spray arc
The spray arc is not suitable for positional welding, due to the
extremely liquid nature of the welding pool. The spraying arc
forms by welding at the higher range of ampere using inert
gas or mixtures with high argon content. The most typical
characteristic of the spray arc is the short circuit free transfer
of extremely fine droplets.
Working range at MAG welding
Principle of msg-soldering
The process of msg-soldering is very similar to the proc-ess
of msg-welding. Because of the lower temperature,the base
material is not fuzed but jointed by melting thesolder which
coates the materials.
10 Basics of the MIG/MAG welding pro-
cess
Welding
Process
Shielding Gas
Inert Active
MIG Helium (He)
Argon (Ar)
Mixtures of
Ar/He
MAG-C Carbon dioxide
100 % CO
2
MAG-M Mixtures of
Ar/CO
2
Ar/O
2
arc
contact tip
gas nozzle
wire electrode
wire feed rolls
power source
workpiece
shielding gas
welding seam
wire diameter
Long arc /
Spray arc
Transitional
arc
Short circuit
arc
mm A V A V A V
0,8 140…
180
23… 28110…
150
18… 2250…
130
14…
18
1,0 180…
250
24… 30130…
200
18… 2470…
160
16…
19
1,2 220…
320
25… 32170…
250
19… 26120…
200
17…
20
Favourable welding characteristic are only possible if voltage and
current are correctly adjusted.
CO2 requires an arc voltage approx. 3 V higher than gas mixtures
with a high argon content.
Page 9
9
Holding and manipulating the torch
)
Metal shielded gas welding can be welded in all positions: horizontal, vertical-down, vertical-up, overhead
and in horizontal-vertical position.
At horizontal welding hold the torch vertical to the workpiece
(neutral torch position) or up to 30° “pushing” the torch. At
thicker welds, a slight dragging motion is sometimes used.
For best depth of penetration and covering of shielded gas is
the neutral position of the torch the most suitable one. Please
notice if the torch is tilted to far, it could be that possible that
air will be sucked into the shielded gas atmosphere (injection
effect).
At vertical and overhead welding a slight pushing motion is required. Vertical down welding is most used for thin materials,
for this kind of weld hold the torch at the neutral or slightly
“dragging” position. For this kind of welding is some experi
ence required cause the welding pool could run ahead and
cause some lacks welding. With thicker material there is a
danger of lacks of fusion cause the welding pool is very liquid
due to high voltage.
Avoid extreme side to side movements to avoid that the welding pool will be damed up in front of the arc. This could cause
lacks of fusion due to the welding pool flows ahead of the
welding spot. The side to side motion should only be as wide
as is necessary to reach both sides of the joint. If the joint is
wide enough you should weld two parallel string beads.
At vertical-up position the side to side motion should describe
the shape of an open triangle.
Length of the arc
Welding with a longer arc reduces the penetration, the welding bead is wide and flat with increased spattering. The welding material is transferred with slightly larger drops than at
welding with a shorter arc.
Welding with a shorter arc (at the same amperage) increases
the penetration, the welding bead is narrow and high with re
duced spattering. The welding material is transferred with
smaller drops as long as the welder is not welding wi th short
arc.
Length of the wire electrode
The distance between the torch and the workpiece should be
10 -12 times the diameter of the wire. Altering the distance of
the torch will influence the length of the electrode end.
A longer electrode end reduces the amperage and the penetration.
A shorter electrode end increases the amperage if the wirefeed speed remains the same.
Please keep attention to the current safety regulations at all
care and maintenance works.
The machine requires minimum of care and maintenance.
Only a few items should be checked to ensure a trouble free
long term operation.
– Please check regularly the mains plug , mains cable,
torch as well as the ground connection for damages.
– Once or twice a year please clean the machine with dry
low compressed air. Switch off the machine and pull out
the plug first. Open the case of the machine and clean
also inside - please avoid to blow directly onto
electronic parts - they could be damaged.
welding direction draggingwelding direction pushing
long arc
short arc
long electrode end
short electrode end
11 Care and maintenance
Page 10
10
12 Troubleshooting
Symptom Cause Remedy
Torch too hot contact tip is not tight check it
No function when torch
button is pressed
nut of the torch hose is not tight tighten it
no connection of the control cable in the torch hose. check and change if necessary
overload of the machine and thermal protection is in
function (control lamp 39 indicates overload)
allow machine to cool down at no load
Irregular wire feeding or
wire welds to the con
-
tact tip
wire electrode is tight at the spool check and change if necessary
burr at the wire beginning cut the wire beginning again
Irregular wire feeding or
no wire feeding
wrong contact pressure at the wire-feed rolls adjust it as described in the manual
torch defect check and change if necessary
no brass pipe in the central connection or is dirty install or clean the brass pipe
bad quality of welding wire check and change if necessary
rust formation at the welding wire check and change if necessary
torch liner is dirty inside disconnect the torch from the machine, screw
off the contact tip and clean the liner with com
-
pressed air
torch liner is dejected check and change if necessary
motor brake adjusted to strong adjust as described in the manual
main rectifier defective check and replace, if required
Machine switches off duty cycle overloaded, control lamp 39 indicates
overload
allow the machine to cool down
to less cooling of machine parts check the air in and outlet
Arc or short circuit between contact tip and
gas nozzle
spatter built up inside the gas nozzle remove it with special pliers
Unstable arc wrong diameter of contact tip or worn out chan ge contact tip
No function of fan phase missing in the mains check machine at another socket and check
mains and fuses
Mains control lamp 40
does not light
phase missing in the mains check machine at another socket and check
mains and fuses
No shielded gas gas cylinder empty replace it
defect torch check and replace it
pressure reducer dirty or defect check and replace it
valve of gas cylinder defect replace the gas cylinder
Shielding gas switches
not off
valve of gas cylinder dirty or does not close remove torch and pressure reducer and clean it
with compressed air
Not sufficient shielded
gas
wrong adjusted quantity of shielded gas adjust right as described in the manual
dirty pressure reducer check valve
torch, gashose blocked or not air-tight check and change if necessary
shielded gas is blow away from draught avoid draught
Less welding performance
phase missing check machine at another socket and check
mains and fuses
poor ground connection ensure best contact between ground clamp
and workpiece
ground cable not right plugged in fasten ground cable by turning the plug to the
right
defect torch repair or replace it
main rectifier defective check and replace, if required
Hot plug of ground cable plug was not tightened by turning to the right check
Higher wire wear out at
wire-feeding unit
wire rolls does not fit to the wire diameter install right wire rolls
wrong contact pressure at wire feeding adjust as described at the manual
Page 11
11
Feed Variant, Steel/Aluminium
Only for EU countries.
Do not dispose of electric tools together with
household waste material!
In observance of European Directive 2002/96/EC on waste,
electrical and electronic equipment and its implementation in
accordance with national law, electric tools that have reached
the end of their service life must be collected separately and
returned to an environmentally compatible recycling facility.
Lorch Schweißtechnik GmbH
Postfach 1160
D-71547 Auenwald
Germany
Telephone: +49(0)7191/503-0
Fax: +49(0)7191/503-199
We herewith declare that this product was manufactured conform to following standards: EN 60 974-1/-10, EN 61 000-3-2,
EN 61 000-3-3, conform to the guidelines 2006/95/EG,
2004/108/EG
08
Wolfgang Grüb
Director
Lorch Schweißtechnik GmbH
Lorch Schweißtechnik GmbH
Postfach 1160
D-71547 Auenwald Germany
Tel. +49(0)7191 503 -0
Fax +49(0)7191 503-199
Internet:www.lorch.biz
E-Mail:info@lorch.biz
Date of issue: 26.03.2008
Subject to change
13 Options
Table of variations Use
Roll
alu
Roll
steel
Standard S t andard at 2 rolls feeding units. Suitable for steel and aluminium, depending
on wire-feed roller in use.
Standard at 4 rolls feeding units. Due to the straightening effect of the roll less
wire friction in the torch. For use with thicker or hard wires.
14 Disposal
15 Service 16 Certificate of conformity
17 Publisher
Page 12
Lorch Schweißtechnik GmbH Postfach 1160 D-71547 Auenwald Germany
Tel. +49 (0)7191 503-0 Fax +49 (0)7191 503-199 info@lorch.biz www.lorch.biz
Loading...