MERKLE MobiARC 280 cel Operation Manual
Operation Manual
Stick Electrode Welding Unit
Model MobiARC 280 cel
Model MobiARC 280 cel ±
Content
1
Content
1. Introduction ................................................................................................................................................... 2
2. Safety instructions ....................................................................................................................................... 3
2.1 Safety instructions before introduction ....................................................................................... 4
2.2 Accident prevention ........................................................................................................................... 4
2.2.1 Safety instructions ......................................................................................................................... 4
2.3 Duty cycle ............................................................................................................................................. 6
2.3.1 Filter attachment ........................................................................................................................... 6
2.4 Instructions to avoid interference .................................................................................................. 6
2.4.1 Evaluation of the installation site ............................................................................................. 7
2.4.2 Procedures to reduce emitted interference ............................................................................ 7
3. Introduction ................................................................................................................................................... 9
4. Controls and displays ................................................................................................................................ 10
5. Manual electrode welding operation .................................................................................................... 13
5.1 To perform the Basic settings ........................................................................................................ 13
5.2 Hotstart settings for the welding current and the parameter ............................................. 14
5.3 Energy regulation with remote controller ................................................................................. 15
6. TIG (WIG) welding ...................................................................................................................................... 16
7. Technical data MobiARC 180 cel ........................................................................................................... 17
8. Technical Data MobiARC 280 cel ± ....................................................................................................... 18
9. Maintenance ................................................................................................................................................ 19
10. Spare parts ............................................................................................................................................... 20
11. Circuit diagrams ..................................................................................................................................... 24
12. Conformity Attestation for MobiARC 280 cel ............................................................................... 28
13. Conformity Attestation MobiARC 280 cel +- ................................................................................ 29
Introduction
2
1. Introduction
MERKLE welding units are capital equipment of special
class. We set high standards in the field of quality and
reliability. Technical innovation and permanent further
development of reliable technique are naturally for us.
Specialised knowledge is premise for handling the
welding units. Safety instructions are defined in detail.
You as responsible user, have to follow the instructions
of the operating manual.
The operating manual is addressed to qualified welding
experts. Only skilled technical staff has to carry out the
service and repair work.
This documentation explains the safety instructions, the
functions, the operation and the maintenance of your
welding unit. In the appendix you find tables with
reference values for your instrument settings,
schematic diagrams, conformity attestation and lists of
important equipment.
Safety instructions
3
2. Safety instructions
The follow safety instructions serve for your own safety as well as prevention of damages at
your welding unit. For this reason, please read the safety instruction heedful before starting and
follow the safety instruction during the work.
Protect yourself and your surroundings against arc loads!
• Arc loads can induce irreversible damages on your eyes as well as
flash burns at your skin. For this reason you have to use a shield with
proper protection class and wear not inflammable clothes.
• Insulate your work area from other people, so that arise no risk
through the arc loads.
Decide arrangements for prevention of burnings!
• Remove inflammable objects out of your work area.
• Do not weld in the area with inflammable atmosphere.
• Make sure that possible burnings can be fast erased (fire drencher,
fire blanket).
Pay attention to the handling of the gas bottles!
• Gas bottles have to put in a proper holder and it have to secured
against tilting over.
• Gas bottles with damaged or leaky valves are to be put out of action
immediately.
• Gas bottles are only with screwed protection cap transportable.
• After end of work you have to close the bottle valve.
Do not operate the machine in wet surroundings!
• Infiltrated wetness can induce electric shock and damage your
machine.
Safety instructions
4
2.1 Safety instructions before introduction
The welding unit is build after 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.
2.2 Accident prevention
The accident prevention regulation is applied for MMA stick electrode and TIG welding unit,
model MobiARC 280 cel.
BGR 500 section 2.26 (earlier VGB 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.
2.2.1 Safety instructions
This unit is manufactured according to the requirements and stipulations of EN 60974.1 / VDE
0544 part 1. BGR 500 (earlier VBG 15) of the trade association for engineering and electrical
engineering are as well valid.
Welding, cutting and allied working process
1) In cause of an accident you have to cut the mains from the welding power source
immediately.
2) You have to deactivate the machine from mains and it has to be checked from skilled expert
or it has to be checked from our service staff if it arise electrical contact voltage at the case.
3) If you have repair or upgrade work, you will cut the mains before you open the case.
4) Repair work may only be carried out by a skilled electrician or by our Service Department.
5) You have to check your machine, your welding torch and the mains plug for external
damages before every introduction.
6) Personal protective equipment in accordance with DIN EN 175, DIN EN 379 and
DIN EN 169.
The welder has to protect his complete body against radiation and burnings through protective
clothes and face protection during the work. In the process you have to wear gauntlets, aprons,
welding shield with protective filter (DIN EN 470-1 and BGR 189). You must not wear synthetic
clothes or sneakers instead you should wear high shoes and you have to wear a headgear if
necessary. The special equipment must be in accordance with the aforesaid and recognized
standards if you use that.
Safety instructions
5
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 BGR 500 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 during welding with increased electrical hazard
Welding rectifier and welding power source have to be designed with „S“ after EN 60974-1
and BGI 534, if it appears direct current (DC) or alternating current (AC). Use insulating
materials against electrical contact as well as wet bottoms. You have to wear dry and
undamaged work clothes as well gauntlets and shoes with rubber sole. Vent the rooms,
install possible suctions and wear gas masks if it necessary (see detailed statement BGR 500
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 BGR 500). When installing the ground
connection, assure that there is a good electrical contact (remove rust, paint, etc.).
9) During the welding pauses, the welding torch is to be laid down on an insulated surface or
hang up in such a way that it is not in contact with the workpiece and is support connected
to the welding power source (see BGR 500). 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 cylinder must always be protected against tumble down using a safety chain.
11) Under no circumstances the unit may be put into operation while it is opened. Apart from
safety regulations, sufficient cooling of the electrical components provided by the fan
cannot be guaranteed.
12) In accordance with BGR 500, persons 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.
13) No welding work may be carried out on containers in which gases, fuels mineral oils or
similar substances have been stored. (explosion hazard). See §31 UVV BGR 500ÖEven if
they have been empty for a long timeÕ See § 31 of accident prevention regulation BGR
500.
14) 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.
Safety instructions
6
15) Never bring the torch to your face. When the torch switch be unintentional put on is it
possible that you will be injured by the wire.
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
fireguard 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 workplace „Caution! Do
not look into the arc!”
2.3 Duty cycle
The duty cycle measurings have been carried out in accordance with EN 60974-1 / VDE 0544
part 1 (10 min working period).
60% duty cycle means:
After 6 minutes welding period must be carried out a welding pause from 4 minutes.
The electrical components are thermally protected against overheating.
2.3.1 Filter attachment
The duty cycle from the unit will be reduced if you use filter attachment. Though is the air
permeability of the filter mats important. Entscheidend ist dabei die Luftdurchlässigkeit der
Filtermatten. The frequency of cleaning is dependent from the degree of utilisation and from the
workplace relationships. If you change the filter mats, you have to use only the original filter
mats with the article number 005.0.1048.
!!! If you ignore this statement, the warranty claim will be voided!!!
2.4 Instructions to avoid interference
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 instructions. If electromagnetic interference is detected, it is the responsibility of
the users of the welding equipment to find a solution with the technical assistance of the
manufacturer´s. 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".
Safety instructions
7
2.4.1 Evaluation of the installation site
Before installing the welding equipment, the user must evaluate potential electromagnetic
problems in the vicinity. The following must be considered:
¾ Other power cables, signal and telecommunication cables above, below and next to
the welding equipment.
¾ Radio and television transmitters and receivers.
¾ Computer and other control devices.
¾ The health of the peoples in vicinity, for example the use of pacemakers 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.
2.4.2 Procedures to reduce emitted interference
a) 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.
b) 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.
Safety instructions
8
c) Welding cables
Welding cables should be kept as short as possible and routed close together on or near
the floor.
b) Equipotential
It is available 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.
c) 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.
d) 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.
Introduction
9
3. Introduction
The unit must be secured against unintentional fall down. The air intakes must be free otherwise
there is danger of overheating. Make sure that no metallic abrasive dusts can be absorbed with
the cooling air. Metallic abrasive dusts are electrically conductive and these can lead to internal
arcing. These internal arcing can damage the device.
Attention! If extension cable be used:
• Only use lines with a minimum diameter of 2.5 mm².
• Unroll the entire cable drum (hazard of overheating)
Attention! If it be put into operation with a power unit:
• The rated power output of the power unit must be at least 10%
greater than the maximal power input of the welding unit.
• The open circuit voltage of the power unit must be regulated
otherwise stress peaks can damage the unit.
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