MERKLE M 450 DW, M 550 DW Operation Manual
Operation Manual
MIG-MAG Welding Unit
Typ M 450 DW
Typ M 550 DW
MERKLE
Schweissanlagen-Technik GmbH
Industriestrasse 3
D-89359 Koetz,
Germany
Tel.: ++49-8221-915-0
Fax: ++49-8221-915-40
www.merkle.de
.
Content page
1st Security indications before introduction 3
2nd Accident prevention regulations 3
2nd1 Safety instructions 3
3rd Duty cycle 5
4th Instructions to avoid interferences due to electromagnetic influences EMC 5
5th Technical Data 7
5th1 MIG/MAG welding unit model M 450 DW 7
5th2 MIG/MAG welding unit model M 550 DW 9
6th Start Up 11
6th1 Installation of the Machine 11
6th2 Main Supply 11
6th3 Earth Lead (Work Cable) 11
6th4 Welding Torch 11
6th5 Gas Connection 11
6th6 Wire Installation 11
7. MIG/MAG Series M 450/550 11
8th Settings 14
8th1 Functions of the settings 0
9th Adjustments 3
9th1 Adjustment M 450 DW for mild steel wire 3
9th2 Adjustment M 550 DW for mild steel wire 4
10th Options 5
10th1 Welding Stainless Steel 5
10th2 Welding Aluminium 5
11th Aluminium Welding 5
12th Maintenance 7
13th Cleaning 7
14th Trouble Shooting 7
14th1 Machine does not operate after switching on the main switch 7
1
14th2 Machine does not react on the torch switch 7
14th3 Control LED (red) is on 7
14th4 Water pump is running, control LED (red) is on 7
14th5 Control LEDs (yellow) and (red) are on 7
14th6 Machine has no or too low welding current 7
14th7 Welding quality is poor 8
14th8 Problems with wire feeding and wire contacting 8
14th9 Burning of the liner 8
15th General Information MIG/MAG Welding Units 8
15th1 Metal Inert Gas Welding (MIG) 8
15th2 Metal Active Gas Welding (MAG) 8
15th3 Protective Gases 8
15th4 Welding Wires 9
15th5 Duty cycle 9
16th Wire feeder systems 9
16th1 Spare parts wire feeder model: DV-25 10
16th2 Spare parts wire feeder model: DV-30 13
17th Welding-Torch and Spare parts 17
17th1 MIG-MAG-welding torch model SB/SBT 502 W 17
18th Spare part list and wiring diagram 22
18th1 Spare part list M 452 DW, M 552 DW 22
18.2 Wiring diagramm M 450DW / M 550 DW 23
19e EU-Conformity Attestation M 452 DW 28
20e EU-Conformity Attestation M 552 29
2
1st 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.
2nd Accident prevention regulations
The following accident prevention regulation is applied for welding with MIG/MAG welding
unit, type M 450 DW, M 550 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.
2nd1 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.
3
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) N
o 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!".
4
3rd 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.
4th 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:
¾ 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.
5
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.
6
5th Technical Data
5th1 MIG/MAG welding unit model M 450 DW
with automatic wire feed, technical data:
Primary:
Voltage: 3 x 400 V
Frequency: 50 Hz (60 Hz)
Continuous power: 14.5 kVA
Continuous current: 21 A
Max. current: 36 A
cos phi (450 A): 0.8
cos phi (150 A): 0.85
Secondary:
Open circuit voltage: 17 - 52 V
Welding voltage: 15 - 36.5 V
Welding current: 25 - 450 A
duty cycle 40 %: 450 A (10 min, 40°C)
duty cycle 60 %: 420 A (10 min, 40°C)
duty cycle 100 %: 340 A (40°C)
Protection class: IP 23
Insulation: H
Cooling: AF
Mains switch: 3 phase
Voltage control: 42 steps
6-step coarse selector
7-step fine selector
Gas Check: button with hold function
and timer switching
Spot welding time: programmable
Intermission time: programmable
Inegrated functions: - wire feed automatic
- storage of wire trim
values (1050 positions)
- high speed wire insertion
automatic
- safty cut-off in 4-stroke
- wire soft start
- ignition automatic
- on-demand control of
fan and water pump
Digital display: current, voltage, material
thickness and wire feed
speed with pre-display
and hold function (option)
Choke: 2-step, 60 % and 100 %
Norm: EN 60974-1 "S" / CE
Torch cooling: integrated water cooler
7
Weight: 220 kg
Dimensions l x w x h: 1040 x 510 x 990 mm
incl. gas bottle holder
Gas bottle holder: 10, 20, 50 l cylinders
Mains supply cable: 4 x 4.0 mm², 5 m long
Gas hose: 2 m long
Socket 50 mm²: 2 sockets for earth lead
Lifting eyes: 4 pieces (option)
Wire feeder: model DV-25
Supply voltage: 26 V-DC
Wire feed: 4-roller drive 0.5 - 25 m/min.
Wire burn back: potentiometer
Wire trim: potentiometer ± 30 %
Operation mode: 2-stroke/4-stroke/stitch/
spot welding
Wire trim selecting: potentiometer on wire feeder/
at TEDAC torch
Material selection: mild steel/stainless steel/
aluminium/special
Wire selection: diameter 0.8/1.0/1.2/1.6 mm
+ special
Reel hub assembly: D 300/15 DIN 8559
Weight: 18 kg
Dimensions l x w x h: 640 x 425 x 175 mm
Torch connection: EURO connector
Connection cable: 1.6 m, 95 mm², water cooled
Standard wire equipm: steel 1.2 mm
Wire feeder: model DV-30 (Option)
technical data see model M 550 DW
Standard accessories:
Earth lead 95 mm², 4 m long 022.1.0403
with plug and earth clamp
Regulator argon/CO2, single stage 012.0.0300
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5th2 MIG/MAG welding unit model M 550 DW
with automatic wire feed, technical data:
Primary:
Voltage: 3 x 400 V
Frequency: 50 Hz (60 Hz)
Continuous power: 22.8 kVA
Continuous current: 33 A
Max. current: 52 A
cos phi (500 A): 0.8
cos phi (150 A): 0.82
Secondary:
Open circuit voltage: 18 - 62 V
Welding voltage: 15 - 42 V
Welding current: 25 - 560 A
duty cycle 40 %: 560 A (10 min, 40°C)
duty cycle 60 %: 500 A (10 min, 40°C)
duty cycle 100 %: 450 A (40°C)
Protection class: IP 23
Insulation: H
Cooling: AF
Mains switch: 3 phase
Voltage control: 42 steps
6-step coarse selector
7-step fine selector
Gas Check: button with hold function
and timer switching
Spot welding time: programmable
Intermission time: programmable
Inegrated functions: - wire feed automatic
- storage of wire trim
values (1050 positions)
- high speed wire insertion
automatic
- safty cut-off in 4-stroke
- wire soft start
- ignition automatic
- on-demand control of
fan and water pump
Digital display: current, voltage, material
thickness and wire feed
speed with pre-display
and hold function (option)
Choke: 2-step, 60 % and 100 %
Norm: EN 60974-1 "S" / CE
Torch cooling: integrated water cooler
Weight: 260 kg
Dimensions l x w x h: 1110 x 530 x 1065 mm
incl. gas bottle holder
9
Gas bottle holder: 10, 20, 50 l cylinders
Mains supply cable: 4 x 6.0 mm², 5 m long
Gas hose: 2 m long
Socket 50 mm²: 2 sockets for earth lead
Lifting eyes: 4 pieces (option)
Wire feeder: model DV-30
Supply voltage: 42 V-DC
Wire feed: 4-roller drive 0.5 - 30 m/min.
with wire straightener
and tacho motor
Wire burn back: potentiometer
Wire trim: potentiometer ± 30 %
Operation mode: 2-stroke/4-stroke/stitch/
spot welding
Wire trim selecting: potentiometer on wire feeder/
at TEDAC torch
Material selection: mild steel/stainless steel/
aluminium/special
Wire selection: diameter 0.8/1.0/1.2/1.6 mm
+ special
Reel hub assembly: D 300/15 DIN 8559
Weight: 21 kg
Dimensions l x w x h: 640 x 425 x 175 mm
Torch connection: EURO connector
Connection cable: 1.6 m, 95 mm², water cooled
Standard wire equipm: steel 1.2 mm
Standard accessories:
Earth lead 95 mm², 4 m long 022.1.0403
with plug and earth clamp
Regulator argon/CO2, single stage 012.0.0300
10
6th Start Up
6th1 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 23.
The air in the surroundings must be free from extreme quantities of dust, free from acides and
corrosive gases etc. Otherwise use air filters.
6th2 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 protection earth must be done.
6th3 Earth Lead (Work Cable)
The earth lead must have an excellent ground. The clamp should be attached to a clean, paint
and rust free area on the work piece or on the welding table.
6th4 Welding Torch
Attach the hose assembly to the Euro-connector with the flange nut.
6th5 Gas Connection
Place the gas bottle on the gas bottle holder and secure it with the safety 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.
6th6 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 tightening 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 tightening 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 ok.
7. MIG/MAG Series M 450/550
The series M 450/550 consists of step switched MIG/MAG welding units form 450 to
560 A welding current. The features are:
- Precise setting of the welding current due to max.
42 steps M 450 and M 550
- Selector: 2-stroke/4-stroke/stitch/spot welding
- Adjustable intermission and welding time
- Adjustable of the wire burn back
- Perfect ignition due to dynamical soft start automatic
- Safty cut-off in 4-stroke operation
- High speed wire insertion automatic
- Automatic switching of the fan
11
- 4-roller wire feeding system DV-25 as a standard (only M 450 DW)
- High performance wire feeder DV-30 as a standard in model M 550 DW and available
as an option for M 450 DW versions
- Digital read-out of the welding voltage and -current (with hold function) and of the
wire feed speed (with pre-display)
- 2-stage choke mounted for reduced spatters
- Integrated water cooling system with efficient water pump in version DW
- Lowered galvanized gas bottle holder (10 l, 20 l or 50 l cylinders) assures a safe
positioning of the cylinders
- Approved of operation in confined areas, “S”-symbol
- Easy handling of the unit due to big and robust swivel and carrier wheels
- Connection for push pull torch or remote control
- NEW: wire adjusting automatic
Easy and precise setting of the correct wire feed speed in each welding range
12
Front Panel M 450 und M 550
9
8
10
15 14 1312
V
V
m/min
mm
E 2867-35
HOLD
20
15
25
30
10
5
0
5
10
25
15
20
8
9
7
6
5
4
3
1
2
7
TEDAC
%
-+
30
KORREKTUR DRAHT/WIRE TRIM
10
0
RÜCKBRAND/WIRE BURN BACK
17
16
456
18
GAS
PROGRAMM
5
4
3
2
6
1
7
6
5
4
2
3
23
13
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