MERKLE HighPULSE 450, HighPULSE 550 DW Operation Manual

OPERATION MANUAL

Pulsed-Arc-Welding Units

HighPULSE 450 and 550 DW

MERKLE Schweißanlagen-Technik GmbH, Industriestr. 3 D-89359 Koetz, Germany

Tel.: [phone], Fax: [phone], e-mail: [e-mail], www.merkle.de

1

directory page

1 Security indications before introduction 4

2 Accident prevention regulations 4

Safety instructions 4

3 Duty cycle 5

4 Instructions to avoid interferences due to electromagnetic influences EMC 6

5 Technical Data: 7

Wire feeder model DV-31 8

6 Start-up Procedure 9

Machine Installation/Connection to the Mains 9

Wire Feed Unit

it

9

Connection to Gas and the regulation of Gas supply. 10

Installation of the Wire Reel. 10

Installation of the Earth cable 10

Transport 10

7 General Details of the HighPULSE 450/550 DW 10

HighPULSE 450/550 DW Power Supply 11

Ventilation Control 11

Water cooling system 11

Wire Feed Un 11

Electronics 11

TEDAC-System 11

Interpulse-welding 12

8 Front Panel 13

Front Panel and Display Guide 13

Front Panel and Display Guide 14

Wire Feed Unit Display Guide 14

9 Standard functions 14

Switching the machine on 14

Choosing a Process 14

9.1.1 MIG/MAG- und Pulse-Arc Welding Programs 14

9.1.2 Interpulse Welding 15

9.1.3 MMA Welding 15

9.1.4 TIG Welding (Option) 16

2

Operation Modes 16

9.1.5 2-Stroke-Operation 16

9.1.6 4-Stroke-Operation 16

9.1.7 4-Stroke-Operation with selected program 16

9.1.8 The programming of Start Current, Down slope current/Time 16

9.1.9 Safety Cut Off Switch 17

Digital Display Panel 17

Wire feed only Buttons 17

Gas Test 17

Selecting the Current control 18

9.1.10 Potentiometer 18

9.1.11 Wire Feed Unit Potentiometer 18

9.1.12 TEDAC 18

9.1.13 JOB-Functions 18

10 Maintenance 19

11 Cleaning 19

12 Maintenance Inspection 19

13 Problem Solving 20

14 Aluminium Welding 23

15 Wire Feed Unit DV-31 25

16 Torches and Spare Parts 27

17 Wire diagrams 30

18 EU-Conformity Attestation HighPULSE 450 DW 37

19 EU-Conformity Attestation HighPULSE 550 DW 38

3

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 using
the trained staff from our establishments or appointed dealers.

2 Accident prevention regulations

The following accident prevention regulation is applied for pulse arc welding unit, model
PU 400 DW and PU 520 DW.

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.

4

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, grid-type 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 even if they have been empty for a long time (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!".

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:

5

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 60974-10 / VDE 0544-part 10 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:

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

and next to the welding equipment

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

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

6

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.

5 Technical Data:

HighPULSE HighPULSE

450 DW 550 DW
primary:
power supply: 3 x 400 V 3 x 400 V
frequency: 50 Hz 50 Hz
continous power: 14,4 kVA 19,4 kVA
continous current: 25 A 28 A
max. current: 34 A 45 A
cos phi: 0,98 0,98

sekundary:
no load voltage: 72 V 72 V
working voltage: 15 - 36,5 V 15 - 41,5 V
welding current: 20 - 450 A 20 - 550 A
duty cycle at: 20°C 40°C 20°C 40°C
35 % duty cycle (10 min.): 550 A
40 % duty cycle (10 min.): 450 A
50 % duty cycle (10 min.): 550 A 480 A
60 % duty cycle (10 min.): 440 A 380 A 510 A 430 A
100 % duty cycle: 370 A 310 A 420 A 350 A

7

Protection class: IP 23
Insulation class: H
Cooling: AF
Arc length: automatic energy control
Program capacity: 512 programs
Programs: MIG/MAG, MIG Pulse, Interpuls,
MMA/stick electrode, DeepArc,
MIG brazing
Program selection: material, wire diameter and gas
at the display
Operation modes: 2-stroke, 4-stroke, 4-stroke with
start current
Gas check: button with hold function
and automatic switch off
Digital display: current, voltage, wire feed speed
and material thickess with
pre-display and hold function
Energy adjustment: at the machine,
at the wire feeder,
at the TEDAC torch,
job mode
LEDs: mains, failure, temp. protection,
hold function
Adjustable parameters: choke inductance, pulse shape
Automated functions: wire burn back,
soft start (programmable)
Job mode: 512 jobs programmable
Power source: inverter
Sockets 50 mm²: earth lead and electrode cable
Torch cooling: integrated water cooler
Mains supply cable: 4 x 6.0 mm², 5 m long
Gas hose: 2 m
Gas bottle holder: for 10, 20 and 50 l cylinders
Stabilization: ± 10 % power mains fluctuation
Norm: EN 60974-1 "S" / CE
Weight: 155 kg (incl. wire feeder)
Dimensions l x w x h: 1030 x 480 x 1170 mm
(incl. wire feeder and rotary device)

Wire feeder: separately mounted, model DV-31:

Supply voltage: 42 V
Wire feed: 4-roller drive 0.5 - 30 m/min.
with wire straightener
and tacho motor
Potentiometer: energy
Potentiometer: arc length (voltage trim)
Button: wire inching
Reel hub assembly: D 300/15 DIN 8559
Weight: 21 kg
Dimensions l x w x h: 610 x 400 x 180 mm
Torch connection: EURO connector
Connection cable: 1.6 m, 95 mm², water cooled
Standard wire equipment: mild steel 1.2 mm

8

6 Start-up Procedure

Machine Installation/Connection to the Mains

a) Should the machine arrive in a cold condition, i.e. after transportation or as a result of storing in

an unheated storeroom, then the machine must first be allowed enough time to adjust itself to the
appropriate ambient work temperature, before allowing any further operation to proceed. It must
also be noted that machine must be sited with no obstructions to the air intake at the front of the
machine and also the air exit point at the rear of the machine (the minimum all-around work area
requirement is approx. 80 cm). The airflow to the machine must not exceed -10°C and +40°C.

b) The assembly/installation area should be a room with a relatively low humidity value (up to 50% at

40 °C and 90% at 20°C)

c) Welding machines supplied complete with a dust filter are tested to IP23 Quality control standard

and can therefore also be used safely in damp conditions.

d) The surrounding air must be as free as possible from unnecessary contamination such as dust, acid,

corrosive gasses or similar substances. In situations of high air contamination (e.g. grinding dust),
an intake air filter must be used

e) Connection to a mains power supply is to It. EN- and VDE- standard and should only be carried out

by a qualified engineer. The connection and circuit breaker details are shown on the technical
specification plate.

Wire Feed Unit

During machine welding the wire feed unit is separated from the welding machine. Between the

welding machine and the wire feed unit an umbilical cord (standard length 5,7,10,15 or 20m) is
used. If the unit is directly fixed to the machine then the umbilical cord length is 1,6m. The
welding torch itself is attached to the machine by means of a standard EURO adapter, providing no
other agreement has been made. The wire feed system uses our standard 4-roller mechanism.
Wire feed rollers and welding torch liners will vary depending on whether Aluminium or Steel is in
use with the machine, the standard wire diameters are 0,8/1,0/1,2 and 1,6mm. Other wire
thicknesses (e.g. core-fluxed wire) can also be arranged on consultation with Merle. The motor
from the wire feed unit is automatically controlled, dust proof, and can correctly function at
working temperatures of 60-70 °C. The complete package meets EN 60974-1VDE 0544-teil 1, and
can also be used in areas of high electrical activity.

Standard wire feed reels are to be used in conjunction with this machine, however with the correct

adapter, Merkle part Nr 029.0.0104 , basket wire reel of the type k300/15 can also be used. The
weight of a standard Steel and Cr-Ni alloy wire reel is 15kg, An Alu. reel weighs 7kg. (EN 440/DIN
8556 and DIN 1732)

Only Reel adapter, Article-No 029.0.0104 may be used on this equipment,

All pieces of residue wire must be removed from the reel housing area,

Failure to do so will result in the loss of the machines factory warranty.

Connection of the Welding Torch

 Plug the male Euro connecter of the torch into the female Euro adapter on the front of the

wire feed unit and twist the screw thread adapter until it is tight.

 Connect the water cooling pipes via the snap connecters to their correct adaptors on the

front of the wire feed unit. (blue-Water in, red- Water out.

9

Connection to Gas and the regulation of Gas supply.

First place the gas bottle onto the gas bottle holder and secure using the supplied chain. Remove

the gas bottle top and purge the bottle valve. Then attach the supplied Gas Regulator correctly
and slowly open the bottle valve.

The optimal recommended Gas flow settings are between 8-20 l/min, depending on the parent

material, weld settings and work position and workplace conditions.

For correct installation follow these simple steps

 Open Gas bottle Valve
 Press the torch trigger
 Turn the regulator gas feed screw until the desired gas flow is on the regulator gauge is

acquired. If a more accurate reading is required then attach a gas flow calibration kit to the
welding shroud and set the desired flow rate.

Installation of the Wire Reel.

Remove the reel retaining nut and place the reel over the wire feed centre post, ensuring that the

male nipple and female adapters on the underside of the reel are correctly engaged. Then return
the reel retaining nut and screw down hand tight. Release the wire from the reel by cutting
cleanly where the wires natural end is secured to the reel. Then release the roller wheel tensioners
and guide the wire through the wire feed guide into the Roller guides. Lay the wire in the grooves
on the feed rollers and hold, then lay the roller tensioner back over the wires and fix. Feed the
wire using the wire feed tester button through the complete torch. If a 10cm spool of wire can be
fed under light resistance, into your hand then the wire feed tensioner is set correctly.

Installation of the Earth cable

Place the male adapter on the end of this cable into the female adapter on the front of the

machine and twist to the right until secure. The earth clamp must be secured correctly to the
work piece i.e. the removal of all paint and rust, or any other contaminants from the weld-site.

Transport

For transportation by crane it is important that all the provided lifting points are used and that a

small as possible lead to the vertical angle is employed. The Gas bottle must be removed from is
platform and transported separately.

7 General Details of the HighPULSE 450/550 DW

The Pulse-Arc welding system HighPULSE 450/550 DW was developed for universal use in hand

and automated production procedures. The wire feed unit can be mounted directly to the welding
machine by means of a turntable. It is also possible with the correct umbilical cord, for the wire
feed unit to be placed up to 20m away from the power unit provided that the cable can be
correctly supported by means of a cable outrigger system.

In conjunction with this the Electrically Isolated Outrigger System,

Merkle Part-No 005.0.2878 must be fitted and used.

Failure to do so will result in the loss of the Factory Warranty.

10

HighPULSE 450/550 DW Power Supply

This welding system was developed around inverter technology.
The current from the power supply is first fed through a rectifier; due to the fact that the now

exiting DC current cannot be transformed it is then electronically scrambled. Thereafter MOSFETs
are employed as a quick reacting switch. The scrambled current is then converted into the
necessary current voltage and amperage; this is achieved through a control system that charges
the current to a condenser which in turn discharges the current in the necessary alternating form
to a transformer. The transformer then produces an alternating current with the frequency of the
original scrambled current, thereafter the current is rectified to a current that is absolutely ideal
for use as Pulse-Arc, MIG/MAG, MMA and TIG welding.

The frequency of the alternating current is responsible through an electro physical principle for the

size of the necessary transformer, e.g. a normal 50 Hz transformer producing a welding current of
approx. 400A weighs approx. 120kg. Through employing this Inverter technology, a transformer
clocking 100 kHz only weighs approx 3kg.

Ventilation Control

The ventilation system is controlled automatically through an on demand system. The run on time

of the cooling system is determined through temperature control system.

Water cooling system

The HighPULSE 450/550 DW has an integrated water cooling system with its own water pressure

switch and corrosion free radiator. The max output of the water pump is 7,5l/min and the max
pressure of 3bar. The motor is protected through an overload circuit breaker. The water pump is
automatically activated through the striking of the arc and the run on time is determined by a
timing device.

Wire Feed Unit

The wire feed unit is controlled by a constantly regulated reluctance motor with a star wheel gear

(DV 31). Coupled to the motor is a monitoring tachometer that constantly controls the RPM output
of the motor. This is then transferred through a Merkle standard 4 wheel drive roller system.

Electronics

The electronic system is broken down into 4 main categories:

 Display, Logic- and mode of operation
 Current regulation, Puls form program settings
 Temperature control, air control and pulsewave modulation
 Wire feed regulator for the wire control unit

The individual circuit boards equipped with easily accessible measurement points for use by a

service engineer. During production function tests are carried out separately with a multitude of
different test apparatus, to which a further function control test is carried out during the final
assembly of the machine. Thereby every machine that leaves the building undergoes function test
before it is released.

TEDAC-System

The TEDAC-system is a control system that enables the user the ability to regulate the welding

current through its full range, using a regulator mounted on the welding torch itself. This is
achieved using the already installed wire loom from the torch to the control board, in a torch with
a standard Euro connector. There is no need for extra cables or the need for an extra control
system to be built into the machine. The maximum setting for the welding current available
through the TEDAC system is controlled/set through the Energie potentiometer mounted on the
front face of the machine. Also the user is able to confirm his settings through the optical

indicator mounted on the welding torch
Green - Minimum Energy
Red - Maximum Energy

11

Interpulse-welding

The Interpulse welding process is activated in the middle range of the welding process. During

which the selected energy setting is transformed into a pulse formed energy, this has the function

of less heat input into the work piece at lower settings and at higher settings produces a much

finer scaling effect in the weld bead.

12

8 Front Panel

191817

16

14 1513

11

7 8 9

1210

2 1345

E 3258-07

6

Lichtbogenlänge

voltage trim

Energie / energy

0

5

10

15

20

25

30

5

10

15

20

25

30

0

10

20

30

40

50

60

70

80

90

100

PP und Fernregelung

pp and remote control

-+

%

Drahtvorschub

wire feed

%

26

27

30

29

25
28

13

Front Panel and Display Guide
(see diagram)
0: mains power switch
1: current potentiometer dial (also on wire feed unit)
2: arc length correction dial (also on wire feed unit)
3: welding process control method switch
4: torch trigger mode switch
5: welding process selector switch
6: rotary program and confirmation (press) selector switch
7: digital current indicator panel
8: LED hold switch
9: digital indicator panel (shared)
10: material thickness (mm)
11: wire feed speed (m/min.)
12: voltage (V)
13: selector switch for upper display
14: LED mains connection
15: LED overheat
16: LED fault indicator
17: wire feed test switch (also on feed unit)
18: gas flow test switch
19: MultiFunktionalDisplay (MFD)

Wire Feed Unit Display Guide

(see diagram)

25: current potentiometer
26: arc length correction potentiometer
27: wire feed test switch
28: current remote switch (Option)
29: remote arc length correction switch (Option)
30: remote connection socket (Option)

9 Standard functions

Switching the machine on
To switch on the machine turn the mains power switch to position 1. the water pump will then activate
and the machine is ready to use. Should LED 16 light up the first check if enough coolant is in the tank, or
if the water pump has activated.

Choosing a Process
Using rotary switch 5 the user can select between the MIG/MAG, Pulse Arc, Interpuls, MMA or TIG welding
processes.

9.1.1 MIG/MAG- und Pulse-Arc Welding Programs

Rotary switch 5 must be switched to either the MIG/MAG or Pulse position. The desired welding program
may now be selected in conjunction with Rotary switch 6 and the use of the Multi Function Display (MFD

19). Turning Rotary switch 6 through a clockwise direction will enable the following Main Menus:

14

Material
New Job
Throat thickness
Impedance (MIG/MAG) or Pulse form (Pulse)

In the Main Menu select Material, by pressing the Rotary switch (6) once a secondary menu listing all
materials will appear, by turning switch 6 and pressing on the desired material that material is selected
and the next Menu field is activated. The next Menu field is titled Filler wire size, by turning and pressing
Rotary switch 6 the desired filler wire size can be selected. The final sub menu to appear is titled Gas,
again through turning and pressing Rotary switch 6 the desired gas can be selected from the list. By
pressing switch 6 one last time the menu table is exited and the chosen program is activated and ready for
use.

Using Dial (1) the desired welding current may be selected, with Dial (2) the Arc-Length (Arc Trim) can be
individually adjusted for each job. If the user wishes to use the wire feed unit to select the desired current
and arc length (switches 25, 26), then the symbol for the Wire feed unit must be selected using switch 3.
Using switches 28, 29 (Option) the control of Current and Arc length setting is transferred to a remote
regulator, i.e. push me pull you torch.

9.1.2 Interpulse Welding

Rotary switch (5) must be rotated into the inter-pulse position. Using the MFD (19) and rotary switch (6)
the following 5 Main Menu’s be activated;

Material
New job
Throat thickness
Interpulse
Pulse form

Using rotary switch (6), select from the main menu ‘Interpulse’, by now pressing the switch (6) the cursor
will return to the program last used in this mode. The programmable inter-pulse range runs from 0 – 100.
The smaller the number the quicker the Pulsing, this gives the weld bead a very fine Scaling appearance. A
larger number would indicate an overall slow Pulse and consequently a larger scaling appearance in the
weld bead. To save the selected inter-pulse setting simply press switch (6) once.

9.1.3 MMA Welding

Rotary switch (6) must be rotated into the ‘Electrode’ position. Important, no load voltage is immediately
present at the cable connection plugs. Using the MDF (19) and the Rotary switch (6) the following 4 sub­menu’s can be accessed;

Hotstart t (time)
Hotstart I (current)
Arc force (current trim)
New Job

The relevant settings can be selected through these sub-menus and altered to suite. The required settings
can also be programmed under a job number.

Hotstart

Hotstart is a process whereby the current to the electrode is increased for a programmed time during the
start phase of the MMA process.

15

Available settings:

Hotstart time 0 – 2s

Hotstart current 20 – 450/550 A

Arcforce (current trim)

• A current increase is delivered through the electrode as a result of the electrode coming into
contact with the weld pool.

• The increase in current ensures that the electrode does not stick to the work piece, however
should this phenomenon occur the current is automatically reduced in order to avoid the
overheating of the electrode.

9.1.4 TIG Welding (Option)

Operation Modes

9.1.5 2-Stroke-Operation

Operation Switch (4) into the „2-Stroke“ position.
Press trigger and hold, welding starts, release trigger, welding program ends.

9.1.6 4-Stroke-Operation

Operation Switch (4) into the „4-Stroke“ position.

1) Press trigger and hold – welding pre-program initiates up to start current

2) Release trigger – main welding current is initiated

3) Press trigger and hold – current will reduce as programmed, up to end current setting

4) Release trigger – the welding program will end

9.1.7 4-Stroke-Operation with selected program

Operation switch (4) into the spezial 4 stroke position.

1) Press trigger and hold – programmed pre-program initiates up to selected start current

2) Release trigger – programmed welding current is initiated

3) Press trigger and hold – programmed down slope and end current is initiated

4) Release trigger – programmed end gas time initiated, when complete the program is ended

9.1.8 The programming of Start Current, Down slope current/Time

9.1.8.1 Start Current (only programmable in special 4 stroke mode)

Program selector switch (5) must be r position ‘MIG/MAG’, ‘Pulse’ or ‘Interpulse’. Using Rotary Switch (6) in
conjunction with the MFD (19) select the Parameter Start Current then press Rotary switch (6) once, the
display will switch to the last programmed setting. Using Rotary switch (6) turn until the desired current is
displayed.

• Programmable settings: 0 to a maximum value corresponding to the chosen
materials programmed parameters.

In order to leave the program with the saved setting, simply press switch (6) once, the cursor will the
return to the initial menu ‘Start Current’.

9.1.8.2 Down Slope Time (only programmable in 4 Stroke/4 Stroke Special Mode)

Selection and programming of the Down slope time is carried out by turning Rotary switch (6) until the
menu heading ‘Down Slope’ shows in the MFD and then press Switch (6) once to select. By turning switch
(6) select the value, in seconds, required.

• Programmable settings: 0 – 10 seconds
To confirm and save the settings simply press Switch (6) once. The cursor will return to the Down Slope
time initial menu.

16

9.1.8.3 End Current (only programmable in 4 Stroke/4 Stroke Special Mode)

Selection and programming of the End Currant is carried out by turning Rotary switch (6) until End
Current shows in the MFD (19), press switch (6) once to enter the menu side. The current level is then
selected by turning Rotary switch (6) until the desired current is shown.

• Programmable Settings: 0 to a maximum value corresponding to the chosen materials
programmed parameters.
To confirm and save the settings simply press Switch (6) once. The cursor will return to the End Current
time initial menu.

9.1.9 Safety Cut Off Switch

As an additional safety feature, if after 2 minutes no arc is initiated then the welding program will be
ended automatically.

Digital Display Panel

The welding machine is equipped with two 3-figure digital displays (7 & 9). These control the indicated

setting possibilities and the ‘Hold’ function; to this end before you begin welding or after you have made a
current (7), voltage (12), wire feed speed (11) or material thickness input change, these digital displays will
indicate the relevant condition that will be delivered.
After welding is complete the machine will retain the last used complete welding conditions until such
time as a change is made manually to the conditions. This is shown through LED (8) lighting up, indicating
that the program has been held.

Upper Display (9)
Using rotary switch (13) select between:
Welding Voltage (12)
Wire feed speed in m/min (11)
Material thickness in mm (10)
In MMA mode the No Load Voltage would be indicated, during welding the actual Welding Current would
be indicated.

Lower Display (7)
This display will always show the Welding Current in Ampere.

Wire feed only Buttons
Using button (17) on the Main Machine or button (27) on the Wire Feed Unit, the welding wire can be fed
through to the torch current free.

Gas Test
Using button (18) the gas flow can be tested as follows:
Press button (18): the gas valve will be activated
Release button (18): the gas valve remains active
Press button (18): the gas valve will be de-activated.
As an added safety measure the gas valve will automatically close after 10 seconds should the button not
be manually operated during testing.

17

Selecting the Current control
Rotary switch (3) is used to select between which method of welding current control is preferred.

9.1.10 Potentiometer

With rotary switch (3) in the upper position the welding current and the arc length correction can be

controlled using potentiometers (1 & 2) on the main welding machines control panel. Using switch (28)

the control is transferred to which ever form of remote control is connected at that time.

9.1.11 Wire Feed Unit Potentiometer

With rotary switch (3) in the second position, control of the welding current and arc length correction is

controlled using potentiometers (25 & 26) on the front face of the wire feed unit.

9.1.12 TEDAC

With rotary switch (3) in the TEDAC position the control of the welding current and arc length correction is
controlled through the thumb switch mounted in the back of the welding torch itself. Warning: the
maximum current available is determined through the position of welding current potentiometer (25) on
the front face of the wire feed unit.

9.1.13 JOB-Functions

New JOBs
Rotary switch (3) must be set to control the current setting through the main control panel (1); the wire
feed unit (25), or the TEDAC torch system. Using the multi function display (MFD19) and rotary switch (6)
select the desired welding program, then with the help of the welding current potentiometer and the arc
length correction potentiometer set the desired welding conditions.
With rotary switches (5, 6) select the desired operational mode and welding process. The saving of the new
welding conditions is achieved using rotary switch (6). The switch (6) must be turned until the main menu
heading ‘New Job’ appears, the number of the next free program slot will then appear in the multi
functional display (MFD19) window, by pressing switch (6) once the program will be saved to the machines
memory and the number of that particular program will appear the MFD (19).

The possibility of saving the desired welding conditions to a job number other than the next available free
job is also possible; this is achieved through rotary switch (6). As above the rotary switch (6) must be used
to select the main menu ‘New Job’, when the next available free job appears in the multi functional display
rotary switch (6) can then be used to select the desired program number, by then pressing rotary switch (6)
twice the welding conditions will loaded into the chosen slot. The MFD (19) will then return to the main
menu heading ‘New Job’ to indicate that the transaction was successful.

Important: When a job is saved to a specific job number the complete job including all the fine tuning
elements of the program is saved (e.g. Inductance, pulse form, start current, down slope time, 2-stroke, 4­stroke, MIG/MAG, pulse-arc etc, etc).

Load saved JOB
If there are a number of jobs saved in the machines memory banks, then these programs can be reselected
and loaded back into the machine using rotary switch (3). The menu heading ‘job’ in the MFD (19) is
selected, the cursor will then show ‘Load Job’, again in the middle of the MFD (19) the job shown in the
display is now active and can be used. Notice: Job that appears in the MFD (19) will always be the last
saved program.

Should another previously saved program be required this can be loaded back into the welding machine by
pressing rotary switch (6) once, the cursor will jump across to the smaller job number field in the bottom
right of the MFD (19), by turning rotary switch (6) the desired program can be selected and is now active.
Only saved job programs can be reactivated.

18

If a TEDAC torch system is being used, then using the thumb control button mounted on the torch a
maximum of 10 programs can be selected and activated through this system. The programs should be
selected in ascending order through the MFD (19) i.e. the lowest number should be the first job.

Change JOB
The parameters in each saved job can be adjusted at any time. To achieve this rotary switch (3) must be in
the “JOB” positions, then using rotary switch (9) select the “Change” sub heading, now each individual
parameter is accessible and can be changed through the turning and pressing of rotary switch (9).

10 Maintenance

The maintenance program must include regular thorough cleaning and inspections of the machine. The
frequency of the maintenance program is directly related to the frequency of use and availability of the
necessary workspace to carry out the cleaning and inspection.

Attention: Before any inspection or cleaning program may be undertaken with the machine it must
be totally disconnected from the mains power supply. The machine should also be allowed time to
cool down, an absolute minimum of 3 minutes must be allowed in order that the condenser can
discharge its load.

11 Cleaning

Power Plant  Firstly disconnect from the mains supply.
Unscrew the screws securing the side panels, and remove the side panels. The machine should then be
thoroughly cleaned using a vacuum cleaner. The cooler matrix should be cleaned with compressed air from
the outside inwards. Dust collected on the circuit boards and machine inverter should be removed using
reduced pressure compressed air (approx 0.5 bar – 1 bar). Should the need for detergents be required then
only those recommended for electrical appliances can be employed.

Wire Feed Unit
Wire feed unit should be should also be cleaned using a vacuum cleaner, it is important to note that all
end cuts or small pieces of leftover wire that can establish a contact between the wire feed mechanism
and the wire feed unit casing, must be removed. The reel holder must be regularly smeared (after approx
2t used wire) with graphite grease.

Welding Torch
The welding torch should be inspected every 50kg welding wire used (approx 3x15kg reels) at which time
the torch liner should be thoroughly blown through using compressed air. The contact tip and gas shroud
should also be checked for possible contamination through spatter and afterwards given a coating of anti
spatter spray.

12 Maintenance Inspection

The following general checks must be carried out:

• Check that all possible damage causing leftover filler wire is removed from the machine. All
cables connectors and circuit boards are checked for loose connections, any found must be
rectified immediately.

• The complete torch package should be checked for any form of damage and if damaged then
should be repaired.

• The torch also has fine cooler veins that cannot tolerate large dirt contamination or the build-up
of lime scale.

• When replenishment is required then a cooler fluid with an MKF value of -15°C (Merkle Art-Nr.

107.822) must be used.

19

• The models with water-cooling have 3,5 Litre capacity when connected by a 1,6m connecting
cable.

• Fluid loss (mostly through changing of torch) must be replenished; otherwise the machine could
cut out due to fluid pressure problems.

• If the machine looses too much fluid then the fluid pump may require recharging in order to
remove the unwanted air from the system.

• If a contamination of the cooling fluid occurs then all the fluid must be changed for new. It is
expected that the machine receive maintenance inspections at regular intervals.

• After the inspection has been completed the side panels should be reaffixed and secured into
position be any welding can take place.

13 Problem Solving

Mains power control light does not light up when connected to mains supply.

 check mains connection
 fuse in the main control system defect

System fault control light indicates ‘red’

 under or over voltage from mains
 over voltage trip system has deactivated the water pump
 General problem with the electronic circuitry

Water pump functions after turning on the machine but the ‘red’ control light is on

 Not enough pressure in the coolant system or the pressure valve is defect.

Temperature control light indicates ‘yellow’

 Welding machine has overheated: do not turn the machine off the machine the cooling fans are

required to run, after the machine has cooled down and the temperature light has been reset the
machine can be reused.

Temperature control light ‘yellow’ and fault control light indicates ‘red’

 Fault in temperature sensor device

The machine does not react to the torch trigger being activated

 Torch trigger defect
 Welding process switch in MMA welding position

The machine delivers too low welding current

 Wrong program selected
 Earth cable connect to the wrong pole
 Defect along the torch power cable

Deposited weld bead has bad weld characteristics

 Arc length corrector – welding conditions set wrong
 Wrong gas
 The wire feed roller pressure wrongly set
 The torch liner requires cleaning or has a kink

Porosity in weld pool

 No or too little gas flow

20

 Gas is mixing with air due to a leak in the line. The gas line should be checked from the pressure

gauges to the gas valve in the wire feed unit as follows: open the gas bottle valve then close the
gas valve in the wire feed unit, the pressure on the pressure gauges should remain constant

 Torch shroud or the gas diffuser is heavily contaminated causing poor gas flow to the job
 The gas diffuser is loose or loosely fitted on the torch (results in air being drawn through the torch

liner

 Badly oxidized work piece
 Air getting to the weld site, i.e. extreme movement of the air conditions at the weld site. (increase

gas flow and/or screen weld site)

 Gas flow meter valve is incorrect or 2 in series have been mistakenly fitted to the pressure gauge
 Gas flow to high causing gas saturation at the weld site

Poor wire feed problems causing irregular feed, constant burn-backs or chaffing of the wire on the
contact-tip

 Too much pressure on the wire at the torch end
 Torch liner requires cleaning through
 Torch liner kinked
 Wrong liner fitted
 Check the welding wire for:

o Pressure setting on the wire feed rollers is set correctly
o The surface of the wire is smooth and not contaminated or chaffed
o The wire size is incorrect, too large for the machine set-up

Annealing of the welding wire

 Gas diffuser is loose or the torch coolant pipe is leaking causing the welding current to flow over

the welding wire or torch liner

Overheating of the welding torch

 Check the coolant system
 Confirm coolant flow to the torch: disconnect the water return nipple, switch on machine and

check the coolant flows unhindered into a container

 Distance from work piece too small

Characteristics of Argon-CO

2

welding gas

For steel and mild steel alloys an argon gas mix of approx 8-30% CO

2

mix is required for:

 Protection against porosity in the weld pool
 Larger weld gaps can be bridged
 Spatter free welding
 Higher melting conditions
 Less precision torch control
 Easily capable of welding thin sheet and in positional welding the possibility of using impulse

welding programs

Gas supply

Gas is available in steel bottles filled to a pressure of 200 bar, filled to 10, 20, and 50 litre content. For
the setting of the gas flow a pressure gauge is fitted with a flow meter is used. The gas flow amount is
dependant on:

 The desired gas density
 Type of material to be welded
 Distance from work piece to gas shroud
 Gas shroud diameter
 Welding position and type of weld
 Accessibility of the weld site

21

 For steel welding the gas flow should be approximately between 8-16 l/min for welding currents

ranging from 40-400 A

 By welding currents larger than 400 A the gas flow will be over 16 l/min
 When welding Aluminium the gas setting should be set at higher than with steel

22

14 Aluminium Welding

1. Aluminium welding wire:
Wire diameter 0.8 mm only with push pull torch
Wire Al-Mg 3/5/4.5 Mn (1.0 mm), Al-Si, Al 99.5 (1.0 and 1.2 mm) torch lead max. 3 m
For welding wire 1.6 mm we recommend a torch with a long torch head
Do not store alu wire without the plastic protection cover. Do not use alu wires with oxid.

2. Teflon liner:
For wire 0.8 - 1.2 mm we recomend the teflon liner (red, 2.0 x 4.0) mm (part-no. 022.1.0586)
For (1.2) and 1.6 mm teflon liner (black, 2.7 x 4.7) (part-no. 022.1.0588)
The carbon teflon liner must be installed without any break from the contact tip to the drive roller
Fix the clamping nut at the Euro connector only by hand

3. Wire feeder:
Exchange the brass guidance nozzle to a pvc guidance nozzle (between the two drive rollers) DV-26:
part-no. 012.0.0373.
The insertion nozzle pvc at DV-31 is the same as for steel or stainless steel welding (part.-no: 110.862)
The outgoing tube (pvc) in the Euro connector is monted:
DV-21: part-no. 103.001,
DV-26: part-no. 103.001,
DV-31: part-no. 102.998.

4. Wire feeding rollers:
Exchange the two lower roller to aluminium rollers (U-groove), the rollers at the top may remain pressure
rollers without a groove

5. Pressure of the rollers:
Reduce the pressure to a minimum.
When the alu wire is stopped at the contact tip the rollers must turn without transporting the wire.

6. Insertion of the wire:
Insert the wire without a contact tip at the torch.
Hold the torch cable straight, otherwise the wire could go through the line and the torch lead.

7. Welding torch:
We do not recommend the torch SB/SBT 307 G or SB/SBT 350 G for aluminium welding. Use a ceramic gas
distributor (not fibre glas). Due to the high temperatures the fibre glass may emit a gas which influences
the welding process.
The torches SB/SBT 502 W and SB/SBT 600 W have an open cooling system. Assures that the components
are tightly fitted. Minimum amounts of water will make the aluminium welding impossible.

8. Protective gas:
We recommend argon 4.6, mixtures argon-helium can be used for thick aluminium plates to avoid or
reduce a pre-heating.

-Gas flow for a gas nozzle 17 mm:
wire 1.0 mm: aprox.12-14 l/min.
wire 1.2 mm: aprox. 14-16 l/min.
wire 1.6 mm: aprox. 18-22 l/min.
Avoid smaller gas nozzles.

If the gas hose between gas valve and cylinder is long, an surge of too much gas is released during the
ignition process which could cause porosity. Our wire feeder boxes have a special reduction device
installed. For gas hoses longer than 10 m we recommend the installation of a pressure regulator inside the
welding unit.We recommend a regulator with an integrated ball-flowmeter.

23

9. Position and distance of the torch:
Aluminium is welded in forward position, the torch is tilt aprox. 10 - 20°.
Distance torch to work piece aprox. 10-15 mm. If the distance is too large, the protective gas shield is not
assured. Avoid draught (air movement in the room).

10. Cleanliness:
Aluminium work pieces must be thoroughly cleaned. Clean with alcohol or special aluminium cleaner
Avoid the storage under high humidity.
Remove oxid when aluminium pieces have been stored over a long period.

11. Additional wire equipment:
In our general catalogues in section 10 we offer complete packages for wire equipments.

12. Special 4-stroke:
We recommend to operate in the special 4-stroke mode with a higher start current. The start current, the
down slop and the final current can be adjusted at the digital control unit.

24

15 Wire Feed Unit DV-31

Pos. Nr./no. Bezeichnung Description

A 113.846 DV-Ausrüstung Stahl 0,8 mm (DV-26/31) Kit for mild steel 0.8 mm (DV-26/31)

B 113.848 DV-Ausrüstung Stahl 1,0/1,2mm (DV-26/31) Kit for mild steel 1.0/1.2 mm (DV-26/31)

C 113.850 DV-Ausrüstung Stahl 1,6 mm (DV-26/31) Kit for mild steel 1.6 mm (DV-26/31)

D 113.852 DV-Ausrüstung VA 0,8 mm (DV-26/31) Kit for stainl. steel 0.8 mm (DV-26/31)

E 113.854 DV-Ausrüstung VA 1,0/1,2 mm (DV-26/31) Kit for stainl. steel 1.0/1.2 (DV-26/31)

F 113.856 DV-Ausrüstung VA 1,6 mm (DV-26/31) Kit for stainl. steel 1.6 mm (DV-26/31)

G 113.858 DV-Ausrüstung Alu 0,8 mm (DV-26/31) Kit for aluminium 0.8 mm (DV-26/31)

H 113.860 DV-Ausrüstung Alu 1,0/1,2 mm (DV-26/31) Kit for aluminium 1.0/1.2 mm (DV-26/31)

I 113.862 DV-Ausrüstung Alu 1,6 mm (DV-26/31) Kit for aluminium 1.6 mm (DV-26/31)

J 113.864 DV-Ausrüstung Fülldraht 1,2 mm (DV-31) Kit for core wire 1.2 mm (DV-26/31)

K 113.866 DV-Ausrüstung Fülldraht 1,6 mm (DV-31) Kit for core wire 1.6 mm (DV-26/31)

L 113.868 DV-Ausrüstung Fülldraht 2,0/2,4 mm DV-31 Kit for core wire 2.0/2.4 mm DV-31

M 113.870 DV-Ausrüstung Fülldraht 2,8 mm (DV-31) Kit for core wire 2.8 mm DV-31

O 113.872 DV-Ausrüstung Fülldraht 3,2 mm (DV-31) Kit for core wire 3.2 mm DV-31

0 Einzelkomponenten für Drahtvorschub: Components additional wire equipm.:

0.1 113.742 Druckrolle DV-26/31 Pressure roller DV-26/31

0.2 110.560 Rollenträger DV 26, 31, 30/4 Roller support DV-31, 30/4

25

1 Drahtantriebsringe: Drive rollers:

1.0 113.946 Antriebsring 0,8 + 1,0 Stahl DV-26/31 Drive ring steel 0.8 + 1.0 DV-26/31

1.1 012.0.0272 Antriebsring 1,0 + 1,2 Stahl DV-26/31 Drive ring steel 1.0 + 1.2 DV-26/31

1.2 012.0.0262 Antriebsring 0,9 + 0,9 Stahl DV-26/31 Drive ring steel 0.9 + 0.9 DV-26/31

1.3 113.948 Antriebsring 1,6 + 1,6 Stahl DV-26/31 Drive ring steel 1.6 + 1.6 DV-26/31

1.4 012.0.0281 Antriebsring 1,0 + 1,2 Alu DV-26/31 Drive ring alu 1.0 + 1.2 DV-26/31

1.5 012.0.0282 Antriebsring 0,8 + 1,6 Alu DV-26/31 Drive ring alu 0.8 + 1.6 DV-26/31

1.6 012.0.0291 Antriebsring 1,2 + 1,6 Fülldraht DV-31 Drive ring core wire 1.2 + 1.6

1.7 012.0.0292 Antriebsring 2,0 + 2,4 Fülldraht DV-31 Drive ring core wire 2.0 + 2.4

1.8 012.0.0293 Antriebsring 2,8 + 3,2 Fülldraht DV-31 Drive ring core wire 2.8 + 3.2

2 Einlaufdüsen: Insertion nozzle:

2.1 110.862 Einlaufdüse DV-31, 30/4 (0,8 - 1,6 mm) Insertion nozzle DV-31, 0.8 - 1.6 mm

2.2 110.863 Einlaufdüse DV-31, 30/4 (2,4 - 3,2 mm) Insertion nozzle DV-31, 2.4 - 3.2 mm

3 Führungsdüsen: Guidance nozzle:

3.1 110.552 Führungsdüse DV-31, 30/4 (0,8 - 1,6 mm) Guidance nozzle DV-31, 0.8 - 1.6 mm

3.2 110.553 Führungsdüse DV-31, 30/4 (2,4 - 3,2 mm) Guidance nozzle DV-31, 2.4 - 3.2 mm

4 Auslaufdüse: Outgoing nozzles:

4.1 110.554 Auslaufdüse DV-26, 31, 30/4 (0,8 - 1,6 mm) Outgoing nozzle DV-26, 31, 0.8 - 1.6

4.2 110.555 Auslaufdüse DV-31, 30/4 (2,4 - 3,2 mm) Outgoing nozzle DV-31, 2.4 - 3.2 mm

5 Drahtführungsseelen: Wire cores:

5.1 022.1.0246 Drahtseele für Stahl blau (1,5 x 4,0) Liner for steel (blue) 1.5x4.0
0,6 - 0,8 (1,0) mm, 3 m, komplett 0.6 - 0.8 - (1.0) mm, 3 m long

5.2 022.1.0247 Drahtseele für Stahl blau (1,5 x 4,0) Liner for steel (blue) 1.5x4.0
0,6 - 0,8 (1,0) mm, 4 m, komplett 0.6 - 0.8 - (1.0) mm, 4 m long

5.3 022.1.0244 Drahtseele für Stahl rot (2,0 x 4,0) Liner for steel (red) 2.0x4.0
1,0 - 1,2 mm, 3 m, komplett 1.0 - 1.2 mm, 3 m long

5.4 022.1.0245 Drahtseele für Stahl rot (2,0 x 4,0) Liner for steel (red) 2.0x4.0
1,0 - 1,2 mm, 4 m, komplett 1.0 - 1.2 mm, 4 m long

5.5 022.1.0248 Drahtseele für Stahl blank (2,5 x 4,5) Liner for steel (uncoated) 2.5x4.5
(1,2) - 1,6 mm, 3 m, komplett (1.2) - 1.6 mm, 3 m

5.6 022.1.0249 Drahtseele für Stahl blank (2,5 x 4,5) Liner for steel (uncoated) 2.5x4.5
(1,2) - 1,6 mm, 4 m, komplett (1.2) - 1.6 mm, 4 m

5.7 022.1.0586 Kunststoffseele rot (2,0 x 4,0) Teflon liner for alu and stainl.st.
Alu/VA 0,8 - 1,2 mm, 3 m lang 0.8 - 1.2 mm, 3 m (red, 2.0 x 4.0)
mit Messingauslaufseele with brass outgoing liner

5.8 022.1.0588 Kunststoffseele schwarz (2,7 x 4,7) Teflon liner for alu and stainl.st.
Alu/VA (1,2) - 1,6 mm, 3 m lang (1.2) - 1.6 mm, 3 m (black, 2.7 x 4.7)

6 Kontaktdüsen SB/SBT 300/455/502W: Contact tips SB/SBT 300/455/502W:

6.1 045.1.1814 Kontaktdüse 0,8 mm Cu-Cr-Zr M8 Contact tip Cu-Cr-Zr 0.8 mm

6.2 045.1.1815 Kontaktdüse 1,0 mm Cu-Cr-Zr M8 Contact tip Cu-Cr-Zr 1.0 mm

6.3 045.1.1816 Kontaktdüse 1,2 mm Cu-Cr-Zr M8 Contact tip Cu-Cr-Zr 1.2 mm

6.4 045.1.1817 Kontaktdüse 1,6 mm Cu-Cr-Zr M8 Contact tip Cu-Cr-Zr 1.6 mm

6.5 109.754 Kontaktdüse 0,8 mm Aluminium CuCrZr M8 Contact tip 0.8 mm alu CuCrZr M8

6.6 109.756 Kontaktdüse 1,0 mm Aluminium CuCrZr M8 Contact tip 1.0 mm alu CuCrZr M8

6.7 109.758 Kontaktdüse 1,2 mm Aluminium CuCrZr M8 Contact tip 1.2 mm alu CuCrZr M8

6.8 045.1.1818 Kontaktdüse 1,6 mm Aluminium CuCrZr M8 Contact tip 1.6 mm alu CuCrZr M8

26

16 Torches and Spare Parts

For torch model SB/SBT 502 W

Technical data:

Cooling: water cooled
Mixed gas: 500 A 60 % duty cycle
CO

2

: 500 A 100 % duty cycle
Wire diameter:
Solid wire: 0.8 – 1.0 – 1.2 – 1.6 mm ∅
Aluminium wire: 1.0 – 1.2 – 1.6 mm ∅
Weight: approx. 1300 g/1 m H

The data are corresponding to (U = 14 + 0.05 x I)

Torch model SB/SBT 502 W

MIG/MAG hand welding torch 022.1.1587
model SB 502 W, 3 m, short version

MIG/MAG hand welding torch 022.1.1588
model SB 502 W, 4 m, short version

MIG/MAG hand welding torch 022.1.1581
model SB 502 W, 3 m, long version

MIG/MAG hand welding torch 022.1.1582
model SB 502 W, 3 m, long version

MIG/MAG hand welding torch 022.1.1601
TEDAC, SBT 502 W, 3 m, short vers.

MIG/MAG hand welding torch 022.1.1602
TEDAC, SBT 502 W, 4 m, short vers.

MIG/MAG hand welding torch 022.1.1603
TEDAC, SBT 502 W, 3 m, long vers.

MIG/MAG hand welding torch 022.1.1604
TEDAC, SBT 502 W, 4 m, long vers.

Standard wire equipment: mild steel 1.2

27

MIG Welding torch model SB/SBT 502 W, watercooled

28

Spare parts and consumables:
Pos. Description Part No.
1-6 Torch neck SB/SBT 502 W 022.1.1564

short version

1-6 Torch neck SB/SBT 502 W 022.1.1560

long version

2 Insulation sleeve for 022.1.1574

SB/SBT 502W
3 O-ring 14 x 4 VE 10 pcs 022.1.0077
4 Pressure sleeve for SB/SBT 502 W 022.1.1424
5 O-ring 12 x 4 VE 10 pcs 022.1.0076
6 water coat for SB/SBT 502 W 022.1.1572
7 Insualtion ring SB/SBT 502 W VE 10 pcs 022.1.1421
8 Tip holder SB/SBT 300/502 W VE 10 pcs 022.1.1578
9 Contact tip Cu-Cr-Zr 0.8 mm VE 10 pcs 045.1.1814

9.1 Contact tip Cu-Cr-Zr 1.0 mm VE 10 pcs 045.1.1815

9.2 Contact tip Cu-Cr-Zr 1.2 mm VE 10 pcs 045.1.1816

9.3 Contact tip Cu-Cr-Zr 1.6 mm VE 10 pcs 045.1.1817
10 Diffusor SB/SBT 502W, ceramic VE 10 pcs 022.1.1567

10.1 Diffusor SB/SBT 502, fibreglass VE 10 pcs 022.1.1568
11 Gas nozzle 17 mm VE 10 pcs 045.1.4300

with fastening ring

11.1 Gas nozzle 14 mm VE 10 pcs 045.1.4301

with fastening ring

11.2 Spot welding gas nozzle VE 10 pcs 045.1.4304

with fastening ring

11.3 Gas nozzle 21 mm heavy duty VE 10 pcs 045.1.4305

with fastening ring
12 Contact tip AL/VA 0.8 mm VE 10 pcs 045.1.1812

12.1 Contact tip AL/VA 1.0 mm VE 10 pcs 045.1.1810

12.2 Contact tip AL/VA 1.2 mm VE 10 pcs 045.1.1811

12.3 Contact tip AL/VA 1.6 mm VE 10 pcs 045.1.1813
15 Handle MIG, complete 105.016

with trigger and cover cap
Only for SBT 502 W:
16 TEDAC pc-board ME-BE-10.0 022.1.0800

incl. slide switch and micro switch
18 Trigger for MIG/MAG torch 022.1.0796
19 Micro switch MIG/MAG torch 022.1.0797
20 Spring for switch VE 10 pcs 022.1.0131
21 Complete cable assembly, w.c. 022.1.1642

3 m, with Euro-connector,

without torch, without liner

21.1 Complete cable assembly, w. c. 022.1.1644

4 m, with Euro-connector,

without torch, without liner
22 Water-power-cable 3.0 m long 022.1.0281

22.1 Water-power-cable 4.0 m long 022.1.0282
23 Wire feeding hose cpl. 3.0 m long 022.1.1662

23.1 Wire feeding hose cpl. 4.0 m long 022.1.1664
24 Water hose flow, 3.0 m long 022.1.0290

24.1 Water hose flow, 4.0 m long 022.1.0291
25 Gas hose, 3.0 m long 022.1.0300

29

Pos. Description Part No.

25.1 Gas hose, 4.0 m long 022.1.0301
26 Switch-cable, 3 m long 022.1.0148

26.1 Switch-cable, 4 m long 022.1.0149
27 Protective-hose, 3.0 m long 006.0.1055

27.1 Protective-hose, 4.0 m long 006.0.1054
28 Liner for steel (blue) 022.1.0246

0.6 - 0.8 (1.0) mm, 3 m long

28.1 Liner for steel (blue) 022.1.0247

0.6 - 0.8 (1.0) mm, 4 m long

28.2 Liner for steel (uncoated), 022.1.0248

1.0 - 1.6 mm, 3 m

28.3 Liner for steel (uncoated), 022.1.0249
1,0 - 1.6 mm, 4 m
30 Euro-connection, at torch side 025.1.0150
31 Brass neck for Euro-connection 025.1.0200
32 Kinking-protection, intake 025.1.0100
33 Euro adapter nut 025.1.0300
34 Liner nut VE 10 pcs 025.1.1301
35 Water-return-hose 022.1.0295
36 Coupling nipple no. 3305 025.1.0400
37 Teflon liner for alu and stainl.st. 022.1.0586

0.8 - 1.2 mm, 3 m (red, 2.0 x 4.0)

with brass outgoing liner

37.1 Teflon liner for alu and stainl.st. 022.1.0588

(1.2) - 1.6 mm, 3 m (black, 2.7 x 4.7)

with brass outgoing liner

38.1 Collet for teflon liner 2.0 x 4.0 min 10 pcs 107.554

38.2 Collet for teflon liner 2.7 x 4.7 min 10 pcs 102.997

39.1 Outgoing nozzle pvc, DV-25/4 103.001

for aluminium and stainless steel

39.2 Outgoing nozzle pvc, DV-30/4 102.998

for aluminium and stainless steel, 0.8 - 1.6 mm

1.2 - 1.6 mm, 3 m (2.7 x 4.7 mm)
41 Kinking protection 022.1.1580
42 Spring for kinking protection 022.1.1579
43 Connection nipple for VE 10 pcs 045.1.0201

water-current-cable, torch side

44 Nipple for wire feeding hose at VE 10 pcs 045.1.0312

torch side
Protection hose 26 x 1.5 VE 120 m 027.2.0100
Water hose blue 5 x 1.5 VE 100 m 027.2.0130
Water hose red 5 x 1.5 VE 100 m 027.2.0125
PVC hose with textile 9 x 12 mm VE 100 m 006.0.0103

Only for SB 502 W:
45 Cover cap for TEDAC handle 022.1.0604

* max. length of torch lead for alu: 3 m.

17 Wire diagrams

30

1 2 3 4 5 6 7 8

4321

2 12 12 1 2 1

-V3 -V4

-V1

~~~

+

-

-V2

~~~

+

-

2

1

4

3

2

1

+SQ-A14-X1/2.4
+SQ-A18-X1/2.4

+SQ-A26-X2/4.5

+SQ-A10-X1/2.3

-R3

-F9

+SQ-A26-X13:1/4.5
+SQ-A26-X13:2/4.5

+SQ-V10:4/2.4

+SQ-A26-X12:1/4.3
+SQ-A26-X12:2/4.3

+SQ-V18:4/2.4

+SQ-V5:3/2.2

+SQ-V13:3/2.2

-A1

L1 L2 L3

PE

L1´L2´L3´

ME-EMV-3.1

+SQ-A26-X8:1/4.3
+SQ-A26-X8:2/4.3
+SQ-A26-X8:3/4.3
+SQ-A26-X8:4/4.3

-X0

PE
N
L3
L2
L1

-A0

L1 L2 L3

PE

L1´L2´L3´

ME-EMV-3.1

Erdungs­schraube

-Q1

L1 L2 L3

T1 T2 T3

-A2

1 2 3 4

~~~

+

-

gn

Pr.DC

U<

U>

ge

rt

ME-I44-PG-10

12 12

X5 X7

X8

~~~

+

-

12 12

X4

9VAC

X6

-A3

X12

16 1

Start

gn

T>80

ge

Stoe

rt

+16Va

gn

X11

16 1

+16Vb

gn

ME-I44-PSRS-1.1

1
2
3
4

1
2

X1

1 40

1

X2

10

X3

1 2 3 4

X4

UVS

gn

Istat

ge

Idyn

rt

X5

NTC

18VAC

sw

sw

swgnswrtsw

bl

sw

sw

sw

ws-sw

ws-bl

ws-bn

gn

ws-rt

rt

bl

sw

bn

rt

bl

vio-sw

vio-sw

bl

rt-sw

rt-sw

bl

bl

rt-ge

rt-ws

ws

ws

bl

bl

Ferittring 3 Wdg.

3PH-400V/50-60Hz/PE

NTC

Thermoschalter

Flachbandkabel

flat band cable

Flachbandkabel

Flachbandkabel

flat band cable

Flachbandkabel

Blatt
7

Bl.

1

Projektbez.

Auftragsnr.

Zeichnungsnr.

Highpuls 450-550

Änderung

Datum

gez.

gepr.

Name

Datum

Name

Konrad

03.10.05

Schweißstromkreis

Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet

c
d

a
b

Plotdatum:

29.05.06

Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon [phone] - 0
Telefax 08221 - 32596

=
+

SQ

1 2 3 4 5 6 7 8

-V17

1

2

4

3

-V18

1

2

4

3

-V9

1

2

4

3

-V10

1

2

4

3

-A5

ME-I44-PF-1.0

-A7

ME-I44-PF-1.0

-A9

110

X1

S5S2S3

S4

S1

ME-PI/C-1.1_S3

-A11

110

X1

S5S2S3

S4

S1

ME-PI/C-1.1_S4

-A14

GATE

SOU

GATE

SOU

116

A.B.-S3

X1

ME-I4-GT-1.0

GATE

SOU

GATE

SOU

116

A.B.-S3

X1

ME-I4-GT-1.0

-A15

SOU

SOU

GATE

GATE

ME-I4-GT-1.0

C.D.-S4

1 16

X1

SOU

SOU

GATE

GATE

ME-I4-GT-1.0

C.D.-S4

1 16

X1

-A18

GATE

SOU

GATE

SOU

116

A.B.-S4

X1

ME-I4-GT-1.0

GATE

SOU

GATE

SOU

116

A.B.-S4

X1

ME-I4-GT-1.0

-A19

SOU

SOU

GATE

GATE

ME-I4-GT-1.0

A.B.-S4

1 16

X1

SOU

SOU

GATE

GATE

ME-I4-GT-1.0

A.B.-S4

1 16

X1

-V13

1

2

4

3

-V14

1

2

4

3

-V5

1

2

4

3

-V6

1

2

4

3

-A4

ME-I44-PF-1.0

-A6

ME-I44-PF-1.0

-A8

110

X1

S5S2S3

S4

S1

ME-PI/C-1.1_S1

-A10

110

X1

S5S2S3

S4

S1

ME-PI/C-1.1_S2

-A12

GATE

SOU

GATE

SOU

116

A.B.-S1

X1

ME-I4-GT-1.0

GATE

SOU

GATE

SOU

116

A.B.-S1

X1

ME-I4-GT-1.0

-A13

SOU

SOU

GATE

GATE

ME-I4-GT-1.0

C.D.-S2

1 16

X1

SOU

SOU

GATE

GATE

ME-I4-GT-1.0

C.D.-S2

1 16

X1

-A16

GATE

SOU

GATE

SOU

116

A.B.-S2

X1

ME-I4-GT-1.0

GATE

SOU

GATE

SOU

116

A.B.-S2

X1

ME-I4-GT-1.0

-A17

SOU

SOU

GATE

GATE

ME-I4-GT-1.0

A.B.-S2

1 16

X1

SOU

SOU

GATE

GATE

ME-I4-GT-1.0

A.B.-S2

1 16

X1

-A20

ME-I44-RCD-1.0

-V23

24

3 1

-V24

24

3 1

-V25

24

3 1

-V26

24

3 1

-T1

23

21

13

11

10

9

8

7

6

5

4

3

2

1

-A21

ME-I44-RCD-1.0

-V27

24

3 1

-V28

24

3 1

-V30

24

3 1

-V29

24

3 1

-T2

23

21

13

11

10

9

8

7

6

5

4

3

2

1

+SQ-A3-X11/1.6

+SQ-A3-X2/1.5

+SQ-V1:+/1.2

+SQ-A2-X5:1/1.2

+SQ-A3-X12/1.6

+SQ-V2:+/1.4

+SQ-A2-X4:1/1.4

-L1

-L2

-X3

-X2

+SQ-A26-X9:3/4.7

-A22

2 3 41

4321

+SQ-A26-X9:1/4.7

-X1

+

-Z1

+SQ-A26-X18:4/4.7

+SQ-A26-X18:3/4.7

+SQ-A26-X18:2/4.7

+SQ-A26-X18:1/4.7

-V21

124

3

-V22

124

3

-V7

1

2

4

3

-V8

1

2

4

3

-V11

1

2

4

3

-V12

1

2

4

3

-V15

1

2

4

3

-V16

1

2

4

3

-V19

1

2

4

3

-V20

1

2

4

3

Elektrode

Werkstück

codiert auf S1 codiert auf S3

codiert auf S4codiert auf S2

Flachbandkabel

flat band cable

Blatt
7

Bl.

2

Projektbez.

Auftragsnr.

Zeichnungsnr.

Highpuls 450-550

Änderung

Datum

gez.

gepr.

Name

Datum

Name

Konrad

19.12.05

Schweißstromkreis

Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet

c
d

a
b

Plotdatum:

29.05.06

Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon [phone] - 0
Telefax 08221 - 32596

=
+

SQ

1 2 3 4 5 6 7 8

+SQ-A26-X3:4/4.5
+SQ-A26-X3:3/4.5
+SQ-A26-X3:2/4.5
+SQ-A26-X3:1/4.5

+SQ-A26-X1/4.6

9

10

13

14

17

18

19

16

15

11

12

7

8

6

5

2

1

3

4

+SQ-A27-X3/5.7

20

23

24

22

21

+SQ-A26-X6/4.4
+SQ-A26-X17/4.4

-A24

110

ge

X2

3
4
5
6

1

2

3

4

5

6

1
2

ME-2QR-24/42-2.2

+

-

-

+

X1

42V/AC

TACHO

ANKER/

core

-15V

+15V

U Soll

+5V

GND

X3

Freigabe/

enable

Bremsen/

brake

Freigabe/

enable

gn

max

min

123456789101112

on

T/A
T/A
T/A
A/T
C1
C2
C3
C4
R1
R2
R3
R4

ME-2QR/DIP-1.0

-A25

123456789101112

on

T/A
T/A
T/A
A/T
C1
C2
C3
C4
R1
R2
R3
R4

ME-2QR/DIP-1.0

6

5

4

3

2

1

4321 4321

4

3

2

1

+SQ-A26-X9:4/4.7

+SQ-A26-X7:2/4.5

+SQ-A26-X7:1/4.5

+OP1

-A28-X2

6
5
4
3
2
1

-C1

-A23

1 10

X5

1 6

X3

101 2 3 4 5 6 7 8 91 2 3 41 2 3 4

X2X1 X4

X7

1

6

S1

X8

1

20

1

X9

6

1
2
3
4

X16

10

1

X17

X11

6 1

X13

110

X14

34 1

18

X15

JP1

ME-MTC32-3.2

X10

En
Korr
3,3V

+5V

+24V

-RS232

bn

ws

ge

or

rs

vio

ws

bn gn

sw-gn

ws

bn

rs

vio

ws

rt

bl

sw

vio-sw

bn

vio-ge

ws

bl-gn

vio

sw-rt

rs

sw/ws

Flachbandkabel

flat band cable

Flachbandkabel

flat band cable

Option Push-Pull

0,1uF
1000V

Pinbelegung 10polig. Flachbandkabel

-A23:X5 nach RS232 Schnittstelle

-A23-X5

RS232
1
2
3
4
5
6
7
8
9

10

1
2
3
4
5
6
7
8
9

10

GND

rxd
txd

rts
cts

Flachbandkabel

flat band cable

Blatt
7

Bl.

3

Projektbez.

Auftragsnr.

Zeichnungsnr.

Highpuls 450-550

Änderung

Datum

gez.

gepr.

Name

Datum

Name

Konrad

03.10.05

Steuerstromkreis

Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet

c
d

a
b

Plotdatum:

29.05.06

Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon [phone] - 0
Telefax 08221 - 32596

=
+

SQ

1 2 3 4 5 6 7 8

+SQ-A23-X1:4/3.2
+SQ-A23-X1:3/3.2

+SQ-A23-X1:1/3.2

+SQ-A23-X1:2/3.2

+SQ-A22-X1:4/2.7
+SQ-A22-X1:3/2.7

+SQ-A22-X1:1/2.7

+SQ-A22-X1:2/2.7

-M7

M
=

+SQ-X8:21/3.8

4321

4

3

2

1

4321

2 12 1

1At

4At

4At

2
1

+SQ-A24-X1:4/3.3
+SQ-A24-X1:3/3.3
+SQ-Q1:T2/1.1
+SQ-Q1:T1/1.1

+SQ-X8:8/3.8
+SQ-X8:7/3.8

+SQ-X2/2.8

+SQ-X3/2.8

+SQ-A27-X1:4/5.6
+SQ-A27-X1:3/5.6
+SQ-A27-X1:2/5.6
+SQ-A27-X1:1/5.6

+SQ-A23-X14/3.3

+SQ-A3-X1/1.5

+SQ-A3-X3:2/1.6
+SQ-A3-X3:1/1.6

+SQ-A2-X6:4/1.4
+SQ-A2-X6:3/1.4
+SQ-A2-X6:2/1.4
+SQ-A2-X6:1/1.4

-M5

PE

M

-M6

PE

M

6677889910

10

-M3

PE

M

-M4

PE

M

-X5

554433221

1

-M2

PE

bnswbl

M

-F14

2 1

-S1

123

Hand/Automatik

-X7

1
2
3
4
5
6

-F13

P

Erdungs­schraube

-F7

10At

-F8

1A

-F5

1A

-F4

4A

-F6

4A

-T3

0V

400V

230V

PE

0V
42V
0V

37

440V

400

2,5A0,5A

+SQ-X8:10/3.8

+SQ-X8:9/3.8

-A26

12123456121

X4

X10 X11

X5

2

1
2
3
4

X9

1 2 3 4

X3

40 1X234 1

X1

rt

Calib

1

2

4
3

X8

X14

ME-I44-TIF-1.1

X12

21

X13

1

2

X18

+15V

-15V

Iist

1 2 3 4

+5V

+24V

9VAC

gn

Pumpe

gn

Ventilator

F1F2F3

440V

400V

230V

X16

22VAC

X15

X6

X17

F4

37VAC

42VAC

F5

1234

X7

Gas1

I>0

ge

Gas1

rt rt

ge

I>0HFGas2

4
3
2
1

4 3 2 1 6 5 4 3 2 1

bl

ge-sw

ge-rt

sw-ws

ws

ws

sw

sw-rt

sw-ws

bn

vio

rs

sw

bn

rs

vio

bl-ws

gn

bl

sw-gn

sw ws

bn

sw-ws

ws

ws-sw

rt

ws-bl

ws-bn

bl

ws-rt

rt-ws

rt-ge

rt

sw

gn

gr

ws

sw

bn bn

ws ws

vio vio

rs rs

Lüfter auf Platine

ME-MTC32

Lüfter/

fan

Inverter

Lüfter/

fan

Kühler

Pumpe/

pump

Motorschutz

Brücke bei Option

Automatenanschluß entfernen

remove bridge with option
machine welding connectio

Wasserdruckschalter

Option:

Automatenanschluß

machine welding connection

Flachbandkabel

flat band cable

Flachbandkabel

Blatt
7

Bl.

4

Projektbez.

Auftragsnr.

Zeichnungsnr.

Highpuls 450-550

Änderung

Datum

gez.

gepr.

Name

Datum

Name

Konrad

03.10.05

Steuerstromkreis

Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet

c
d

a
b

Plotdatum:

29.05.06

Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon [phone] - 0
Telefax 08221 - 32596

=
+

SQ

1 2 3 4 5 6 7 8

4

3

2

1

+SQ-A26-X3:1/4.5
+SQ-A26-X3:2/4.5
+SQ-A26-X3:3/4.5
+SQ-A26-X3:4/4.5

+SQ-A23-X9/3.5

+OP1

-A28

rt
Freigabe/

enable

X4

ME-PPMR-2.1

X1

1

2

3

4

5

6

7

8

X2

1

2

3

4

5

6

1 10

X3

JP1

JP2

>3m

1A-träge/

slow

+OP1

-A29

ME-PPMR/AN 2.0

rt

+

rt

gn

0

-

110

X1

-A27

A

V
m/min
mm

Hold

3030

0

20

10

10

20

0

50

20

40

60

90

100

rt

ge

%

- % +

MIG/MAG

PULSE

INTERPULSE

ELEKTRODE

TIG

JOB

TEDAC

ME-MTC32FR-1.1

X6

1

2

3

4

5

6

X4

6

1

1

6

X3

1
2
3
4

X1

12

X2

+5V

+24V

rs

vio

ws

bn

Flachbandkabel

flat band cable

Blatt
7

Bl.

5

Projektbez.

Auftragsnr.

Zeichnungsnr.

Highpuls 450-550

Änderung

Datum

gez.

gepr.

Name

Datum

Name

Konrad

03.10.05

Steuerstromkreis

Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet

c
d

a
b

Plotdatum:

29.05.06

Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon [phone] - 0
Telefax 08221 - 32596

=
+

SQ

1 2 3 4 5 6 7 8

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

+VB

-X8

24

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

-X9

24

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

1

-M1

+

-

+

-

G
=

M
=

+VB

-X9

24

-Y1

+OP1

-X10

B

A

K

J

H

G

F

E

D

C

M
=

E

A

S

E

A

S

-S3

-R1

E

A

S

-R2

E

A

S

-S1

1

2

3

-S2

1

2

3

B

A

-X6

+

+VB

-X1

24

23

21

17

15

14

13

12

10

9

8

7

Energy

BT.

BT.

PP-Motor

Energy

B
A

Option:

PP-und Fernregleranschluß/

remote control

Zentralanschluß

(Ansicht Maschinenfront)

EURO connector

(front view)

VB-Kabel/

connection cable

DV-Gerät DV-30/4

wire feeder

Taster Draht/

botton wire feed

Korrektur/

trim

Korrektur/

trim

Blatt
7

Bl.

6

Projektbez.

Auftragsnr.

Zeichnungsnr.

Highpuls 450-550

Änderung

Datum

gez.

gepr.

Name

Datum

Name

Konrad

04.01.06

DV-Kasten

Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet

c
d

a
b

Plotdatum:

29.05.06

Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon [phone] - 0
Telefax 08221 - 32596

=
+

DV

18 EU-Conformity Attestation HighPULSE 450 DW

EU – Conformity Attestation

Description of the unit: Synergic Pulse Welding Unit

Model: HighPULSE 450 DW

The above mentionned unit complies with the following European Regulations:

EU-Low Voltage Regulation 73/23/EWG
EU-Electromagnetic Compatibility 89/336/EWG

In case of any modifications, incorrect repairs not exclusively authorized by Merkle, this attestation looses
its valdity.

Applied norms EN 60974 - 1 / IEC 974 - 1 / VDE 0544 part 1

EN 60204 - 1 / IEC 204 - 1 / VDE 0113 part 1

EN 60974-10 / VDE 0544 part 10

Kötz, January 12

th

, 2006

Wilhelm Merkle, Generalmanager

Merkle Schweißanlagen-Technik GmbH

37

19 EU-Conformity Attestation HighPULSE 550 DW

EU – Conformity Attestation

Description of the unit: Synergic Pulse Welding Unit

Model: HighPULSE 550 DW

The above mentionned unit complies with the following European Regulations:

EU-Low Voltage Regulation 73/23/EWG
EU-Electromagnetic Compatibility 89/336/EWG

In case of any modifications, incorrect repairs not exclusively authorized by Merkle, this attestation looses
its valdity.

Applied norms EN 60974 - 1 / IEC 974 - 1 / VDE 0544 part 1

EN 60204 - 1 / IEC 204 - 1 / VDE 0113 part 1

EN 60974-10 / VDE 0544 part 10

Kötz, January 12

th

, 2006

Wilhelm Merkle, Generalmanager

Merkle Schweißanlagen-Technik GmbH

38

1st Edition 2006 08.06.2006

Changes reserved.

39