MERKLE CompactMIGPro 210 K, M 211 K, M 306 K, M 306 D Operation Manual

OPERATION MANUAL

MIG/MAG Welding Unit

CompactMIGpro 210 K

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Contents page

1. Security indications before introduction 3

2. Accident prevention regulations 3

Safety instructions 3

3. Duty cycle 5

4. Instructions to avoid interferences due to electromagnetic influences EMC 5

5. Technical Data 7

Synergic MIG/MAG welding unit, type CompactMIGpro 210 K 7

6. Start Up 9

Installation of the Machine 9

Main Supply 9

Welding Torch 9

Gas Connection 9

Wire Installation 9

7. Operation of the Welding Unit COMPACTMIGPRO 210 K K 11

8. General Information MIG/MAG Welding Units 12

Metal Inert Gas Welding (MIG) 12

Metal Active Gas Welding (MAG) 12

Protective Gases 13

Welding Wires 13

9. Maintenance 13

10. Cleaning 13

11. Trouble Shooting 13

Machine does not operate after switching on the main switch 13

Machine does not react on the torch switch 14

Machine has no or too low welding current 14

Problems with wire feeding 14

Problems with wire feeding and wire contacting 14

Welding quality is not good 14

Poor welding results 14

12. Spare part list COMPACTMIGPRO 210 K K 15

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Front view 15

Left side view 17

Right side view 19

13. Wire Feeder model DV 25 19

Spare parts wire feeder model: DV-25 21

14. MIG/MAG Hand Welding Torch 23

MIG/MAG Hand Welding Torch Model SB/SBT 154 G, 25

15. Electrical components and wiring diagramm 27

Electrical components COMPACTMIGPRO 210 K K 27

Wiring diagramm COMPACTMIGPRO 210 K K 28

16. EU-Conformity Attestation COMPACTMIGPRO 210 K K 29

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1. Security indications before introduction

The unit device is built after the recognized standards. Safe works are nevertheless only possible
if you read the operating instructions and the safety regulations contained in it entirely and
obey strictly. Install yourselves by trained staff of our establishments or appointed dealers.

2. Accident prevention regulations

The following accident prevention regulation is applied for welding with MIG/MAG welding unit,
type COMPACTMIGPRO 210 K K:
BGV D1 (earlier VBG 15) * Welding, cutting and allied processes
A copy of this regulation should be readily accessible in every welding shop. The stipulations of
this regulation are to be observed in the interests of safe and correct welding operation.

* Available from the trade association responsible or
Carl Heymanns-Verlag, Luxemburger Strasse 449, 50939 Cologne.

Safety instructions

This unit is manufactured according to the requirements and stipulations of EN 60974.1 / VDE
0544 part 1. BGV D1 (earlier VBG 15) of the trade association for precision engineering and
electrical engineering are as well valid.

1) In case of an accident, the cutting unit must be disconnected from the mains
immediately.

2) If electrical contact voltages arise, switch off the unit immediately, disconnect it from
the mains and proceed to inspection by a qualified electrician or by our Service
Department.

3) Before opening the unit, disconnect it from the mains supply.

4) Repair work may only be carried out by a skilled electrician or by our Service
Department.

5) Before the unit is put to operation, check it visually, as well as the torch and all cables
and connectors regarding possible external damages.

6) Personal protective equipment in accordance with DIN EN 175, DIN EN 379 and

DIN EN 169.

During the work, the welder’s body must be completely protected against radiation and
burns by means of protective clothing and face protection. Long gloves, aprons and
welding shields with welding filters conforming to DIN EN 470-1 and BGR 189
must be worn.
Synthetic clothing are excluded. Shoes must be closed, not opened (due to spatters). If
necessary, protective headwear must be worn (e.g. for overhead welding). If cover
glasses are used, these must be in accordance with the norms specified above.
As additional protection for the eyes against UV radiation, safety goggles with side
shields and corresponding face protection in accordance with BGR 192 and BGI 553
must be worn.
Accident prevention regulation BGV D1 § 27 stipulates that it is the responsibility of the
employer to provide suitable personal protective equipment, while § 28 stipulates that it
is the responsibility of the insured to wear suitable clothing.

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7) Protection when welding under increased electrical risks
Welding rectifiers and welding power sources which can optionally be used for either
direct or alternating current must be marked "S" in accordance with EN 60974-1 and
BGI 534.
Use insulating materials to protect you against contact with electrically conductive parts
and damp floors. Wear dry, undamaged work clothing, long gloves and footwear with
rubber soles. Ventilate rooms, install extraction systems if required, and wear respiratory
protective equipment if necessary (see Procedural instructions BGV D1 § 27 and BGI 533,
Section 5).

8) In order to prevent stray currents and the effects thereof (e.g. destruction of electrical

protective ground conductors), the welding return cable (workpiece cable) must be
connected directly to the workpiece to be welded or to the table (e.g. welding table, grid­type welding table, workbench) supporting the workpiece (see BGV D1 § 20). When
installing the ground connection, assure that there is a good electrical contact (remove
rust, paint, etc.).

9) During welding pauses, the welding torch is to be laid down on an insulated surface or
hung up in such a way that it is not in contact with the workpiece and its support
connected to the welding power source (see § 20 BGV D1).
In the case of longer work pauses, the welding unit must be switched off and the gas
cylinder valve must be closed.

10) The shielding gas cylinder must always be protected against tumbling downing using a
safety chain.

11) Under no circumstances the unit may be put into operation while it is opened

(e.g. for repair work). Apart from the safety regulations, sufficient cooling of the
electrical components provided by the fan cannot be guaranteed.

12) In accordance with BGV D1 § 5, people in the vicinity of the arc must also be informed

of the hazards and protected against them. Safety partitions (“welding safety curtains”)
must be erected in accordance with DIN EN 1598.

14) No welding work may be carried out on containers in which gases, fuels, mineral oils or

similar substances have been stored Öeven if they have been empty for a long timeÕ
(risk of explosion). See § 31 of accident prevention regulation BGV D1.

15) Welds which will be subjected to high loads and which need to meet specific safety

requirements may only be carried out by specially trained and qualified welders.

15) Never bring the torch close to your face.

16) In areas at particularly high risk of fire, the welder must obtain a welding permit and

have this on his person throughout the duration of the welding work. On completion of
welding, a fire-guard must be delegated to ensure fire protection.

17) Ventilation measures must be applied in accordance with BGI 553, Section 9.

18) The hazard to eyesight must be indicated by means of a sign at the work site "CAUTION!
Do not look into the arc!".

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3. Duty cycle

The duty cylce measurings have been carried out in accordance with
EN 60974-1 / VDE 0544 part 1 (10 min working period).
60% duty cycle means:
After a 6 min. welding period a 4 min welding pause must be respected. The electrical
components are thermally protected against overheating.

4. Instructions to avoid interferences due to electromagnetic influences EMC

The welding unit has been manufactured in accordance with the requirements of guideline
EN 50199 regarding electromagnetic compatibility. It is nonetheless the responsibility of the
user to ensure that the welding equipment is installed and operated in accordance with the
manufacturer’s instructions. If electromagnetic interference is detected, it is the responsibility of
the user of the welding equipment to find a solution with the technical assistance of the
manufacturer. In some cases, it may be sufficient simply to ground the welding current circuit.
In other cases, it may be necessary to build a complete shield for the welding power source and
workpiece using the input filters. In all cases, electromagnetic interference must be reduced to
avoid any possible malfunctions.
Note: For safety reasons, the welding current circuit may or may not be grounded. No
modifications may be made to the grounding without the approval of an expert who is able to
determine whether the changes might increase the risk of accidents, e.g. by allowing parallel
welding current return paths which could destroy the ground conductors of other equipment.
Further instructions are contained in TEC 974-XX "Arc welding equipment – installation and
use".

a) Evaluation of the installation site

Before installing the welding equipment, the user must evaluate potential
electromagnetic problems in the vicinity. The following must be taken into
consideration:

a. Other power cables, control cables, signal and telecommunication cables above, below

and next to the welding equipment

¾ Radio and television transmitters and receivers
¾ Computers and other control devices
¾ The health of people in the vicinity, e.g. use of heart pacemaker and hearing aids
¾ Calibration and measuring equipment
¾ Interference immunity of other devices in the vicinity. The user must ensure the

electromagnetic compatibility of other devices used in the vicinity. This may require
additional safety measures.

b) Procedures to reduce emitted interference

1) Mains supply
Welding equipment is to be connected to the mains in compliance with the
recommendations of the manufacturer. If interference occurs, it may be necessary to
take additional precautions, e.g. filters for the mains connection. Make sure that the
power cable of welding equipment is installed in a fixed position shielded by means of a
metal conduit or similar. The entire length of the shield must be electrically connected.
The shield must be connected to the welding power source in the way to obtain a good
electrical contact between the metal conduit and the housing of the welding unit.

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2) Maintenance of the welding equipment
Welding equipment must be maintained regularly in accordance with the
recommendations of the manufacturer. All access and service doors and covers must be
closed and fastened securely when the welding equipment is in operation. No
modifications whatsoever may be made to welding equipment with the exception of
modifications and adjustments specified in the manufacturer’s operating instructions.

3) Welding cables
Welding cables should be kept as short as possible and routed close together on or near
the floor.

4) Equipotential bonding
It is advisable to interconnect all metallic parts in and next to the welding equipment.
Metallic parts connected to the workpiece can, however, increase the risk of the welder
receiving an electric shock by touching these metallic parts and the electrode
simultaneously. The welder must be electrically insulated against all these connected
metallic parts.

5) Grounding the workpiece
If the workpiece is not connected to the ground for electrical safety reasons, or due to
the size and position of the workpiece, e.g. steel structure or outer wall of a ship,
grounding the workpiece may in some cases, but not all, reduce emitted interference. It
must be ensured that grounding the workpiece will not increase the risk of accidents for
the user and cannot cause the destruction of other electrical equipment. If necessary,
the grounding of the workpiece must be carried out by means of a direct connection to
the workpiece. In countries where a direct connection is prohibited, the connection must
be made by means of suitable reactors, selected in accordance with national regulations.

6) Shielding
Selective shielding of other cables and devices in the vicinity can reduce interference
problems. For special applications, it may be worth considering shielding the entire
welding system.

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5. Technical Data

Synergic MIG/MAG welding unit, type CompactMIGpro 210 K

Primary:

Voltage 1 x 230 V 1 x 400 V
Frequency: 50/60 Hz 50/60 Hz
Continuous power: 2.9 kVA 3.6 kVA
Continuous current: 0.73
cos phi (150 A): 0.73 0.76

Secondary:

Open circuit voltage: 42 V 42V
Welding voltage: 15-22.5 V 15-24.5 V
Welding current: 25-170 A 25-210 A
duty cycle 35 %: 170 A (10 min) 210 A (10 min)
duty cycle 60 %(40°C): 90 A (10 min) 110 A (10 min)

Protection class: IP 21
Insulation: H
Cooling: AF
Mains switch: 230 V range 1 + 2

400 V range 1 + 2

Program selection: tip control and LEDs for

2-stroke/4-stroke/stich/spot w.

Remote control: tip control and LEDs for

setting at the TEDAC torch/
setting at the machine

Material selection: tip control and LEDs for

mild steel/stainless steel/alu

Wire selection: tip control and LEDs for

diameter 0.6/0.8/1.0 mm

MIG brazing: special program f. MIG brazing
Energy setting: potentiometer / TEDAC torch
Wire trim: potentiometer
Wire burn back: installed
Spot welding time: potentiometer
Intermission time: potentiometer
Temperature overload: LED
Integr. Functions: - wire feed automatic

- safty cut-off in 4-stroke

- wire soft start

- crater filler

- welding programs

Power source: thyristor
Rectifier: silicon press-in diodes
Choke: 2 sockets for welding and

MIG brazing

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Norm: EN 60974-1 "S" / CE
Torch cooling: gas
Weight: 75 kg
Dimensions l x w x h: 800 x 460 x 620 mm
Gas bottle holder: for 10, 20 l cylinders
Mains supply cable: 5 x 1.5 mm², 5 m long

with plug 3 x 400 V / 16 A

Gas hose 2 m long
Socket 35 mm²: for earth lead

Wire feeder: compact, model DV-26

Voltage: 26 V-DC
Wire feed motor: DC motor with worm gear drive

0.7 - 25 m/min.

Gear: 4-roller-drive DV-25
Reel hub assembly: D 300/15 DIN 8559
Torch connection: Euro connector
Standard wire equip.: mild steel 0.8 mm

Standard accessoreis:

Earth lead 25 mm², 4 m long part.- nr. 022.1.0400
with plug and earth clamp
Regulator argon/CO2, single stage part.- nr. 012.0.0300

Accessories:

Coupling 230/400 V part.- nr. 005.0.1869
Adapter for wire spool part.- nr. 029.0.0104
MIG/MAG hand welding torch part.- nr. 022.1.0858

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6. Start Up

Installation of the Machine

Place the machine at least 0.80 m from a wall etc. to guarantee the cooling air can go
through the unit. The room temperature should not exceed 40°C.
The room were the unit is placed should have a low degree of humidity
(max. 50 % at 40°C, max. 90 % at 20° C).
The unit has passed the quality control in accordance with IP 21.
The air in the surroundings must be free from extreme quantities of dust, free from acides and
corrosive gases etc. Otherwise use air filters.

Main Supply

The main supply must be connected by a trained person. The main supply voltage is displayed on
the front or rear panel of the machine. A connection to ground (GND) must be done.

Welding Torch

Connect the torch to the Euro-connector.

Gas Connection

Place the gas bottle on the gas bottle holder and secure it with the safty chain. Remove
the cap and open the bottle momentarily to purge the valve. Install the regulator on the
bottle valve. Connect the gas hose from the machine to the pressure reducer. Slowly open
gas valve and set the gas flow.

Wire Installation

Place the wire spool over the wire drive. Loosen the end and cut off the bent end section.
Hold the wire to prevent unwinding of the spool. Open the lightning lever and lift the pressure
finger. Feed the wire into the wire feed guide. Push the wire forward onto the
wire drive roller grooves. Close the lightning lever and switch on the machine.

Check the wire feeding: Place your hand 10 cm in front of the contact tip. Let the wire run
into your hand. If the wire is running, the pressure of the drive rollers is o.k.