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

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OPERATION MANUAL

MIG/MAG Welding Unit

CompactMIGpro 210 K

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

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

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.

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!".

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.

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.

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

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

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.

Front view

7. Operation of the Welding Unit COMPACTMIGPRO 210 K K

The machine is operating in synergic mode: welding voltage, welding current and wire feed speed are adjusted with only one buttom (Pos. 5) or by means of the TEDAC torch.

Front View

(see figure)

Pos. 11 main switch with two steps for 400 V (380-415 V) and two steps

for 230 V (220-240 V)

step 1: reduced maximum energy for welding of thin metal sheeds

step 2: full energy

Pos. 15 selector: 2-stroke, 4-stroke, interval, spot welding

2-stroke-operation - LED 14 is on:

Press the torch switch, the wire is running with about 30 of the adjusted wire feed speed. The gas flow is switch on and the no-load voltage is applied to the contact tip.

If the wire has no contact to the workpiece within 5 sec., the gas valve and the no-load voltage are switched off. The wire feed speed is switched to 10 m/min for inserting the wire into the wire core (wire feed automatic).

Release the torch switch and press it again to start the welding process.

4-stroke-operation - LED 13 is on:

1st stroke: torch switch pressed down - the wire is running with a reduced speed

(30 of the welding wire feed speed). As soon as the wire contacts the workpiece the wire feed speed is switch to the welding wire feed speed (wire soft start).

If there is no contact of the wire to the workpiece within 3 sec. while the

torch switch is pressed down, the machine automatically stops the operation

(safty cut-off).

2nd stroke:

torch switch is released - welding with selected energy

3rd stroke: torch switch is pressed down: the welding current is automatically

sloped down from the selected welding current to the minimum current.

4th stroke:

torch switch is released: welding current is switch off.

Interval operation - LED 12 is on:

With the var. resistors Pos. 2 and Pos. 4 the welding and intermission times are selected (range: 0.5 - 2.0 sec.) As long as the torch switch is pressed down, the

interval welding process is operated.

Spot welding - LED 10 is on:

With the var. resistor Pos. 2 the spot welding time is selected (range: 0.5 - 2.0 sec.).

Pos. 9 Selection of the energy control

LED 6 is on: control of the energy directly at the machine with vac. resistor Pos. 5. Scalles are calibrated in material thickness (mm).

LED 8 is on: control of the energy directly at the TEDAC welding torch. Var.resistor Pos. 5 has no function.

Pos. 16 Selection of the welding wire

LED 18: 'St' -mild steel

LED 19: 'CrNi' - stainless steel

LED 20: 'Al' - aluminum and aluminum alloys

Pos. 21 Selection of the diameter of the welding wire

LED 22: 0.6 mm

LED 23: 0.8 mm

LED 24: 1.0mm

After switching off and on the welding unit the last selected parameters are

automatically recalled.

Pos. 3 control of wire trim

+/- 30 change of the automatically selected wire feed speed

Pos. 17 temperature of the welding unit is too high: welding current is switch off. Wait

for cooling down of the machine by the fan and continue welding after LED 17

is off.

Pos. 25 Euro-connection for the welding torch

Pos. 28 connector for earth lead (MIG/MAG welding)

Pos. 29 connector for earth lead (MIG brazing)

8. General Information MIG/MAG Welding Units

MIG/MAG welding is a system where the welding wire is the carrier of the electric arc. Surrounding the contact tip (wire feed nozzle) is the gas nozzle, that emits the protective gas. The welding bead is protected in this way from oxygen contamination.

Metal Inert Gas Welding (MIG)

In this technology inert gases are used. Mostly used are argon, helium, and mixtures of these components. These gases do not react with other materials, they are inert. They are manly used for welding aluminium, copper, titanium or other non ferrum metals.

Metal Active Gas Welding (MAG)

For MAG welding gases like CO2, argon, and mixtures of these components are used. For special purposes also mixtures of C02, argon and oxygen can be used. Mild steel and stainless steel is welded with theses gases.

Protective Gases

The gas flow is depended on several parameters:

- gas density

- material of work piece

- distance gas nozzle to work piece

- diameter of gas nozzle

- geometry of weld

For welding steel and stainless steel the gas flow is in the range of about 8 to 16 I at welding currents of 40 -400 A. For welding aluminium the gas flow is about 30 % more.

Welding Wires

Different diameters of welding wires are available:

0.6 / 0.8 / 0.9 / 1.0 / 1.2 / 1.6 / 2.4 mm.

9. Maintenance

The machine should be cleaned in regular intervals to guarantee a proper operation. The length of the cleaning interval depends on the operation time, surrounding atmosphere etc.

IMPORTANT: Before opening the machine disconnect the main supply!

10. Cleaning

Welding unit: Open the side covers. Remove dust from all parts of the

machine.

Welding torch: Control the welding torch after welding of 50 kg wire.

Remove, clean and replace the wire core. Clean with a cleaning solvent. Blow dry with compressed air. When replacing the wire core, insure that there are no kinks. The gas nozzle must be sprayed with a silicon-free spray to prevent the weld spatters from sticking to the nozzle. The contact tip is a consumable item and must be replaced as required. Attention: Do put oil to the wire core or the drive roller on the wire feed unit.

11. Trouble Shooting

Machine does not operate after switching on the main switch

a) Check main supply

b) Check main fuses

Machine does not react on the torch switch

a) Problem at the torch switch

b) Check internal fuses

Machine has no or too low welding current

a) Bad or no contact at the earth lead

b) Torch hose completely or partially broken

c) Problem with thyristor in the machine

d) Only 2 main phases are connected, check main fuses

Problems with wire feeding

a) Wrong diameter of the contact tip or contact tip must be changed. b) The liner is extremely dirty. c) Kinks in the liner. d) Wrong diameter of the liner. e) Check the pressure of the rollers.

Problems with wire feeding and wire contacting

a) Hole in the contact tip has wrong diameter or contact tip must be changed.

b) Wire core is extremly dirty.

c) Kinks in the wire core.

Welding quality is not good

a) No or too low gas flow b) Air is mixed into the protective gas. Open gas valve and close it again. Gas pressure

must remain in the gas hose. Check at the regulator.

c) Gas nozzle or tip holder are covered with spatters. Gas flow is not o.k.

d) Tip holder is not fixed properly. Air is mixed into the protective gas via the wire

e) Extremly oxidated workpiece.

f) Air is comming to the welding area because of wind.

Poor welding results

a) Protective gas is missing b) Air is mixed into the protective gas. Open gas valve and close it again. Gas pressure

must remain in the gas hose. Check the regulator

c) Gas nozzle or tip holder are covered with spatters. Gas flow is not ok. d) Tip holder is not fixed properly. Air is mixed into the protective gas via the wire e) Extremely oxidated work piece. f) Air is coming to the welding area because of the wind. f) Wrong size of or used rollers are mounted. g) Mechanical resistance of the welding wire is too high.

12. Spare part list COMPACTMIGPRO 210 K K

Front view

Pos. Description electrical. part no.

1 side cover left 005.0.0977

2 knob 003.0.1503

3 knob 003.0.1503

4 knob 003.0.1503

5 knob 003.0.1505

9/15/16/21 switch (mounted on pc-board)

11 main switch Q1 001.0.0058

6/7/8/10/12/13/14/17/18/19/20/22/23/24

LED (mounted on pc-board)

25 euro- connector 002.0.2875

26 front panel 011.0.1039

27 side cover left 005.0.0978

28 socket for earth lead 001.0.1101

29 socket for earth lead 001.0.1101

Left side view

38 39 40 41

444347

Left side view

Pos. Description electrical. part no.

30 power supply cable 5x1.5 mm2, 5,5 m 009.0.1700

31 plugCEE 16 A 012.0.1700

32 cable fixture 001.0.0702

33 main transformer EN 210 A T1 001.0.1918 with thermical switch F6 001.0.0408

34 fan 230 V –AC M2 001.0.1323

choke EN 210A L1 108.848

gas hose

37 gas valve 42 V – AC Y1 002.0.1602

38 control transformer T2 001.0.1819

prim.: 400V/230V

sek. 9V-42V-29V-18V- 9V

39 current converter T3 010.0.1604 with resistor 47 Ohm-0,5 W R5 030.0.1133

40 triac V2 001.0.0189

41 pc-board ME-MAG 20-0/Z A2 003.0.0179

42 resistor 15 Ω -9 W R1/R2 020.1.1090

43 pc-board ME-MAG 20.0 A1 003.0.0178

with E-prom M 20211 CU 16.10.2002 insulating board 002.0.0139

44 capacitors 8 x 10000 µF - 63 V C1 010.0.1900

45 rectifier 210A V1 001.0.0249

46 with thermical switch 90° C F7 001.0.0207

47 varistor S 14K60 R1 010.0.1909

pc-board ME-EMV-1.3 (not shown) A3 003.0.0084

Right side view

59 a-e

Right side view

Pos. Description electrical. part no.

50 swivel wheel 005.0.1205

53 wire feeder DV 25, complete 002.0.2850 motor M1 002.0.2630

capacitor 0,1 µF -1000V C9/C10/C11 001.0.0415

55 handle 005.0.1466

56 cover sheed 005.0.0969

57 insulator 002.0.2954 cap red 003.0.1522

58 insulation plate 002.0.2876 inside insulation 012.0.0285

59a- fuse holder 003.0.1207 59e with cap 003.0.1206

59a fuse 1 At F1 003.0.1212

59b fuse 1 At F2 003.0.1212

59c fuse 0,5 At F3 003.0.1220

59d fuse 0,5 At F4 003.0.1220

59e fuse 3,15 At F5 003.0.1236

60 wire spool holder 002.0.2821

61 middle sheed 005.0.0974

62 safty chain 005.0.0421

63 machine body 005.0.0972

64 gas bottle holder, complete 005.0.0979

65 wheel 005.0.0461

13. Wire Feeder model DV 25

13 15

19 20 21 23

242526

30 32

22 34

E 2715-39

Drahtvorschubgetriebe DV-25

3518

Spare parts wire feeder model: DV-25

(If spare parts for the wire feeder are needed, always indicate number of the relative positon and part number)

Pos Description _Part No._

Wire feed gear complete 002.0.2850 with motor and wire feed rollers 1 gear flange (brass part) 002.0.2875

gear flange (complete) 012.0.0287 (Euro connector preassembled)

2 lentil flat-head screw 090.0.0825

3 insulation bush 002.0.2877

4 knurled screw M 4 x 20 090.0.1002

5 bolt (roller) 002.0.2859

6 bolt 002.0.2864

7 rocking bar 002.0.2865

8 cylindrical pin 090.0.0571

9 thread pole M 8 x 90 002.0.2863

10 knurled nut 002.0.2862

11 compression spring 002.0.2690

12 pressure piece 002.0.2861

13 thread case 002.0.2860

14 rocking bar 002.0.2866

15 bullet button 002.0.2856

16 pvc liner 012.0.0377

17 permanent magnet motor 24 VDC 002.0.2630

18 hexagon screw 090.0.4335

washer 090.0.1208 spring ring 090.0.1408

Pos Description _Part No._

19 insulation plate 002.0.2876

20 gear insulation 012.0.0285

21 gear angle 002.0.2874

22 sheet steel protection 002.0.2870

23 outgoing nozzle (brass) 6 x 2 x 48 002.0.0367

Outgoing tube (brass) for alu/stainless steel 012.0.0369 6 x 0.6 x 45

24 bolt (roller) 002.0.2873

25 for mild steel/stainless steel:

drive roller with groove V ∅ 0,6 mm 002.0.2879 drive roller with groove V ∅ 0,8 mm 002.0.2880 drive roller with groove V ∅ 1,0 mm 002.0.2881 drive roller with groove V ∅ 1,2 mm 002.0.2882

for aluminium:

drive roller ∅ 0,8 mm alu 002.0.2884 drive roller ∅ 1,0 mm alu 002.0.2885 drive roller ∅ 1,2 mm alu 002.0.2886 drive roller ∅ 1,6 mm alu 002.0.2887

26 knurled screw M 4 x 10 090.0.1001

27 fastener 002.0.2869

28 drive pinion 002.0.2871

29 guidance nozzle (brass) for steel 5 x 1,5 x 40 002.0.2867

guidance nozzle for alu/stainless steel 012.0.0373 (pvc) 5 x 1,5 x 40

30 knurled screw 002.0.2857

31 pressure roller 002.0.2878

32 screw (brass) 025.1.1610

33 incoming nozzle 002.0.2891

34 retaining ring 002.0.2858

39 edge protection rubber (0,3 m) 001.0.0820

14. MIG/MAG Hand Welding Torch

Model SB/SBT 154 G

Technical Data:

Mixed gas: 150 A 60 % duty cycle CO2: 180 A 60 % duty cycle Wire diameter: Solid wire: 0.6 – 0.8 mm ∅ Alu wire: 0.8 – 1.0 mm ∅ Weight: approx. 930 g/1 m H

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

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

Pos. Description Part No.

MIG/MAG hand welding torch, model SB 154 G, 3 m 022.1.0738

MIG/MAG hand welding torch, model SB 154 G, 4 m 022.1.0739

MIG/MAG hand welding torch, TEDAC, model SBT 156 G, 3 m 022.1.0752

MIG/MAG hand welding torch, TEDAC, model SBT 156 G, 4 m 022.1.0753

Standard wire equipment: mild steel 0.8

Spare parts and consumables:

1 Torch neck SB/SBT 154 G 022.1.0734 2 Tip adapter, short, SB/SBT 154 G VE 10 St 022.1.0176 3 Contact tip 0.6 mm VE 10 St 022.1.0177

3.1 Contact tip 0.8 mm VE 10 St 022.1.0170

3.2 Contact tip 1.2 mm VE 10 St 022.1.0182 4 Gas nozzle SB/SBT 154 G VE 10 St 022.1.0095 5 Spot welding gas nozzle SB/SBT 154 VE 10 St 022.1.0096 10 Handle MIG, complete 105.016

with trigger and cover cap 13 Cable support for TEDAC handle 022.1.0774 14 Trigger for MIG/MAG torch 022.1.0796 15 Micro switch MIG/MAG torch 022.1.0797 16 Spring for switch VE 10 St 022.1.0131

Only for SBT 154 G:

17 TEDAC pc-board ME-BE-10.0 022.1.0800

incl. slide switch and micro switch 19 Complete cable assembly SB/SBT 154 022.1.0316

3 m, with Euro connector,without torch, without liner

19.1 Complete cable assembly SB/SBT 154 022.1.0317

4 m, with Euro connector,

without torch, without liner 20 Euro connector gas cooled, 025.1.1350

incl. cable support and

adapter nut 21 Brass body for MIG Euro connector 025.1.1401 22 Euro adapter nut 025.1.0300 23 Liner nut VE 10 St 025.1.1301 24 Cable support at Euro connector 025.1.1300 25 Liner for steel (blue) 022.1.0246

0.6 - 0.8 (1.0) mm, 3 m long

25.1 Liner for steel (blue) 022.1.0247

0.6 - 0.8 (1.0) mm, 4 m long

Pos. Description Part No.

26 Teflon liner for alu and stainl.st. 022.1.0586

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

27 Collet for teflon liner 2.0x4.0 mm VE 10 St 107.544

28.1 Outgoing and guidance nozzle pvc, 012.0.0384

DV-20, for alu and stainless steel

28.2 Outgoing nozzle pvc, DV-25 103.001

for aluminium and stainless steel

Only for SB 154 G:

30 Cover cap for TEDAC handle 022.1.0604

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

15. Electrical components and wiring diagramm

Electrical components COMPACTMIGPRO 210 K K

electr. Description part no.

A1 pc-board ME-MAG 20.0 003.0.0178

with E-prom MAG-20210 (COMPACTMIGPRO 210 K K)

insulating board 002.0.0139 A2 pc-board ME-MAG-20.0/Z 003.0.0179 A3 pc-board ME-EMV-1.3 003.0.0084

C1-C8 capacitors 8x10000 uF 63 V 010.0.1900 C9-C11 capacitor 0.1 uF -1000 V 001.0.0415

F1 fuse - control transformer prim. 400 V -1 A 003.0.1212 F2 fuse - control transformer prim. 400 V -1 A 003.0.1212 F3 fuse-fan 230V-0.5 A 003.0.1220

F4 fuse - pc-board 42 V - 0.5 A 003.0.1220 F5 fuse - motor 29 V - 3.15 A 003.0.1236 F6 thermical switch - main transformer 003.0.1236 F7 thermical switch - rectifier 90° C 001.0.0207

L1 choke EN 211 108.848 M1 wire feed motor 24 V – DC 002.0.2630 M2 fan 230V-AC 001.0.1323

Q1 main switch 001.0.0058 R1-R2 resistor 15 Ω - 9 Watt 020.1.1090

R3 var. resistor 10 kOhm – energy 001.0.0545 R4 var. resistor 10 kOhm - wire trim 001.0.0545 R5 resistor 47 Ohm - 0.5 W 030.0.1133 R6-R7 varistor S14K60 at the rectifier 010.0.1909

T1 main transformer EN 210 A (COMPACTMIGPRO 210 K K)

001.0.1918 T2 control transformer prim. 400V/230V 001.0.1819

sec. 9V/42V/29V/18V/9V T3 current converter 010.0.1604

V1 rectifier 210 A 001.0.0249 V2 triac 001.0.0189

X1 euro-connection 012.0.0287 X2-X3 bush 012.0.1509 X1/A1 socket 6-pol. 015.0.0407

X2/A1 socket 18-pol. 015.0.0406 X3/A1 AMP pin socket 4-pol. 016.0.0113 X1/A2 AMP pin socket 2-pol. X2/A2 socket 10-pol. 015.0.0412 X3/A2 socket 4-pol. 015.0.0409 X4/A2 socket 8-pol. 015.0.0410

X5 socket for power supply cable Y1 gas valvel 42 V – AC 002.0.1602