MERKLE PU 400 DW, PU 520 DW Operation Manuals
Operation Manual
Synergic Pulse Welding Unit
Model PU 400 DW
Model PU 520 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
1 Security indications before introduction 3
2 Accident prevention regulations 3
2.1
3 Duty cycle 5
4 Instructions to avoid interferences due to electromagnetic influences EMC 5
5 Technical Data: 7
6 Start Up 8
6.1 Installation of the Machine 8
6.2 Main Supply 8
6.3 Welding Torch 8
6.4 Gas Connection 8
6.5 Wire Installation 8
6.6 Earth Lead (Work Cable) 8
Safety instructions 3
6.7 Transport 9
7 Generalities of the welding unit 9
7.1 Model PU 400 DW / PU520 DW 9
7.2 Cooling of the power modul 9
7.3 Electronics 9
7.4 TEDAC-System 9
8 The indicated numbers below are refering to the drawing of the front panel 11
9 Operation of the Unit PU 400 / 520 DW 11
9.1 Switching on the machine 11
9.2 Selection of the welding process 12
9.3 Setting of the welding energy 12
9.4 Setting of the operation mode 12
9.5 Safety cut off 14
9.6 Adjusting of 'start current', 'down slope' time, 'final current' and 'intermission' time 14
10 Activation of the fixed TEDAC programs (jobs) 15
10.1 Generating your own TEDAC program 15
1
11 Pulse-Arc Welding Units PU 400 DW and PU 520 DW 16
11.1 Advantages – Point by point 16
11.2 Construction of the housing: 17
11.3 Locking of the control panel 17
12 Cleaning 18
13 Maintenance and Accident Prevention 18
14 Trouble Shooting 18
14.1 Machine does not operate after switching on the main switch 18
14.2 Machine does not react on the torch switch 18
14.3 Machine has no or too low welding current 18
14.4 Welding quality is not good 19
14.5 Problems with wire feeding and wire contacting 19
15 Aluminium Welding 19
16 Wire feeder systems 20
16.1 Spare parts wire feeder model: DV-25 22
16.2 Spare parts wire feeder model: DV-30 25
17 Torches - and Spare parts 29
17.1 MIG-MAG-welding torch model SB/SBT 502 W 29
17.2 Push-Pull-welding torch model PP/PPT 502 W 34
18 Stored programs PU 400 39
19 Spare parts and wiring diagram 40
19.1 Spare part list PU 400 DW 40
19.2 wiring diagram PU 400 41
19.3 Spare Part List PU 520 DW 49
19.4 wiring diagram PU 520 50
20 Stored programs PU 520 57
21 EU-Conformity Attestation PU 400 DW 59
22 EU-Conformity Attestation PU 520 DW 60
2
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 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.
2.1 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, 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) N
welding work may be carried out on containers in which gases, fuels, mineral oils or
o
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.
4
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
5
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.
6
5 Technical Data:
Model: PU 400 DW PU 520 DW
Primary:
Power supply 3 x 400 V (415V) 3 x 400V (415V)
Frequency 50 (60) Hz 50 (60) Hz
Continuous power 14.5 kVA 22,1 kVA
Continuous current 21 A 32 A
Max. current 27 A 42 A
Cos phi 0,95 0,9
Secondary:
No load voltage 80 V 77 V
Working voltage 15 - 34 V 15 - 40 V
Welding range 20 - 400 A 20 – 520 A
60 (10 min.) duty cycle 400 A 520 A
100 duty cycle 310 A 440 A
Protection class IP 23 IP 23
Insulation class H H
Cooling AF AF
Pulse frequency 20 - 500 Hz 20 - 500 Hz
Basic current 0 - 400 A 0 - 500 A
Pulse current 0 - 600 A 0-1000 A
Arc voltage 0-80V 0-77V
Pulse time 0,1 - 25,5 ms 0.1 -25.5 ms
Generator Inverter Transistor-cascada
Pulse form 144 pulse forms programmable
Ignition process 13 parameters programmable
Arc length automatic adjusting
Program storage EPROM and EEPROM for 144 programs
Welding process MIG/MAG, Pulse-Arc, Interpulse, stick electrode
Wire diameter 0.8/1.0/1.2/1.6 mm + 2 special
Material selection Programs for 12 materials
Operation mode 2-stroke, 4-stroke with down slope, 4-stroke
with start and final current., stitch, spot welding
Gas check Button with hold-funktion and timer
Digital read-out 2 displays for curr., voltage, wire
feeding speed, material thickness
with pre-indication and hold-function
Energy control continuous; wire feeder or TEDAC-torch;
4 programs recallable at the TEDAC-torch
Wire feeding system DC-tacho-motor with 4-roller dive 0.1-30 m/min.
Torch cooling integrated watercooling system
Norm EN 60974-1 "S" / CE
Weight 140 kg 270 kg
Dimensions L x W x H 1020x470x1015 1110 x 530 x 1065 mm
with wire feeder with wire feeder
and gas bottle holder and gas bottle holder
7
6 Start Up
6.1 Installation of the Machine
If the unit is brought from cold ambient temperatures into a tempered room, for example due to
transportation or from unheated storage depots, it must be adapted before being put to operation a
certain time according to the temperature difference onto the ambient temperature.
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.
6.2 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.
6.3 Welding Torch
Connect the torch to the Euro-connector.
Gas Connection
6.4
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
6.5
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.
6.6 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.
8
6.7 Transport
If a transport by crane is required, the unit must be fixed at all lifting eyes.
7 Generalities of the welding unit
7.1 Model PU 400 DW / PU520 DW
The welding unit PU 400 DW is based on inverter technique, the welding unit PU 520 is a
secondary transistor-switch 20 kHz technologie and suitable for MIG/MAG, Pulse-Arc and
MMA/stick electrode welding. Continuous setting of the welding current up to 400 A (PU 400),
520 A (PU 500).
The unit can be characterized by numerous features:
¾ inverter power source with continuous setting of the current 20 - 400 A (PU 400),
the PU 520 with transistor- cascada with continuous setting of the current 20 - 520 A
¾ socket for remote control
¾ digital read out with pre-display and hold-function
7.2 Cooling of the power modul
The fans which are cooling the power modul are switched on automatically as soon as the arc is
enlighted.
7.3 Electronics
The electronic is divided in to 3 sections:
¾ Display, selection of the logic and the operation mode
¾ Adjusting and program parameters
¾ Supervision of the temperature, fan control
7.4 TEDAC-System
The TEDAC-System offers the possibility to adjust the energy from min. to max. by means of a
slide switch. The poti „energy“ is limiting the range of the welding current.
The multi-coloured LED at the handle inside shows the actual setting of the welding current.
red - max. energy
green - min. energy
9
Front panel
8
8
9
7
10
6
5
4
0
18
25
26
80
90
70
60
50
40
30
100
%
Energie / energy
0
10
20
27
3
2
PULSE
MIG-MAG
1
ELECTRODE
INTERPULSE
TEDAC
TEDAC
4
789
SPECIAL
SPECIAL
AlSi
Al 4,5 Mn
654
1.0 mm
0.8 mm
10
SPECIAL
SPECIAL
CrNi
AlMg 3-5
3
1.2 mm
1.6 mm
12
11
SPECIAL
SPECIAL
SG 2+3
SG 2+3
1
2
2.SPECIAL
1.SPECIAL
E 2923-31
5
639
PP und Fernregelung
pp and remote control
20
15
25
10
5
0
5
10
15
30
%
voltage trim
Lichtbogenlänge
-+
30
25
20
17
Drahtvorschub
19
2
wire feed
7
10
V
V
m/min
mm
GAS
11
HOLD
121513 14
MAIN SWITCH
HAUPTSCHALTER
1
10
8
The indicated numbers below are refering to the drawing of the front
panel
1: main switch
2: selector welding process
3: selector location of energy adjustment
4: selector operation mode
5; selector material
6: selector wire diameter
7: selector read-out
8: variable resistor interpulse / welding timer
9: button gas test
10: digital read out, switchable
11: digital read out, amperage
12: LED HOLD
13: LED mains on
14: LED thermic protection
15: LED failure
17: variable resistor voltage trim / arc length (at the wire feed unit)
18: variable resistor energy (at the wire feed unit)
19: button wire currentless (at the wire feed unit)
21: trimmer down slope time (inside of the generator, on top of the front panel)
22: trimmer final current (inside of the generator, on top of the front panel)
23: trimmer start current (inside of the generator, on top of the front panel)
24: trimmer intermission time (inside of the generator, on top of the front panel)
25: switch remote control energy (at the wire feed unit, option)
26: switch remote control voltage trim (at the wire feed unit, option)
27: socket for remote control or push-pull torch (option)
9 Operation of the Unit PU 400 / 520 DW
9.1 Switching on the machine
Turn main switch ( 1) into position 1.
If the digital read-out (10) and (11) only indicate horizontallines the chosen welding program
does not exist.
For help see selection of the welding programs, otherwise the machine is ready for operation.
Selection of the welding programs
Selection of the material by means of the two selectors (5) and (6).
Put selector (5) in order to choose the material and selector (6) in order to choose the correct wire
diameter.
If the digital read-outs (10) and (11) are only indicating horizontal lines, the welding program
does not exist.
The list of welding programs is displayed at the inside of the wire feeder box.
11
9.2 Selection of the welding process
With selector (2) the welding process can be selected:
MIG-MAG, PULSE, INTERPULSE and STICK ELECTRODE WELDING. If the digital readouts (10) and (11) only show horizontallines, the chosen welding program does not exist.
1. MIG-MAG welding
With variable resistor ( 17) individual adaption of the arc voltage ( arc length)
2. PULSE welding
With variable resistor ( 17) individual adaption of the arc voltage ( arc length)
3. INTERPULSE welding
With variable resistor (17) individual adaption of the arc voltage (arc length). With
variable resistor (8) the interpulse parameters are changed, i.e. left turn is fine scaled
welding, right turn is coarse scaled welding.
Interval welding is not possible in interpulse operation.
4. STICK ELECTRODE welding
With variable resistor ( 17) arc-force is adjusted:
Left turn = no increasing of the welding current
Right turn = maximum increase of the welding current
9.3 Setting of the welding energy
With selector (3) the adjusting selector for the welding energy is chosen.
1. Variable resistor
In this position the energy is set by the variable resistor (18) at the machine. With switch (25) a
remote control box can be used.
2. TEDAC
The welding energy is adjusted by means of the slide switch on the TEDAC-torch and limited to
a maximum value by variable resistor (18).
3. Fixed welding programs (jobs)
See further functions
9.4 Setting of the operation mode
With selector (4) the operation mode is chosen.
2-stroke operation
Selector ( 4) in position “2-stroke”.
In this position the torch interruptor is used to start and to switch off the machine.
12
4-stroke operation
Selector (4) in position “4-stroke”.
Torch interruptor pressed: welding process is started
Torch interruptor released: welding in process
Torch interruptor pressed: welding, “down slope” of the welding current down
to the “final current”
Torch interrupter released: welding arc is cut off
4-stroke operation with special welding program
Selector (4) in position “special 4-stroke”
Torch interrupter pressed: the welding process is started with the “start current”
Torch interruptor released: welding with selected energy
Torch interrupter pressed: down slope” of the energy down to the “final current'”
Torch interruptor released: welding arc is cut off
4. Stitch operation
Selector ( 4) in position “stitch”.
The welding time can be adjusted by variable resistor (8) (range: 0.5- 2.5 sec.) Time of
intermission is adjusted by a trimmer inside the machine.
5. Spot welding
Selector ( 4) in position “spot welding”.
With variable resistor (8) the welding time can be adjusted (range: 0.5 -2.5 sec.)
With variable resistor (8) the start current is adjusted in relation to the selected welding
current (in % )
Insertion of the wire
With button (19) the wire is inserted without welding current.
The feeding speed increases slowly up to approximately 15m/min.
Testing shield gas
With button (9) the gas flow can be checked. Button (9) pressed: gas valve is switched on, Button
(9) released: gas valve is still switched on, Button (9) pressed: gas valve is still switched on
Button (9) released: gas valve is switched off or the gas valve is automatically switched off after
10 s
Digital read-outs
The welding unit is equipped with two digital read-outs.
These digital read-outs dispose of the pre-indication and HOLD-function of the welding
parameters, i. e. indication of the preselected welding current and welding voltage (or
wire feed speed or thickness of material).
13
After the welding process the last welding values are hold as long as LED (12) is enlighted or the
arc is enlighted again or the welding energy is changed.
Upper display (10):
With selector (7) following parameters can be displayed:
a) welding voltage in V
b) wire feed speed in m/min
c) material thickness in mm
Stick electrode welding: the actual welding voltage is always indicated.
Lower display (11 ):
The welding current is always indicated (in amps. )
9.5 Safety cut off
In case of no arc is established within about 2 s, the welding process is automatically cut off in
any selected operation mode.
9.6 Adjusting of 'start current', 'down slope' time, 'final current' and 'intermission' time
(These trimmers are located inside of the generator on top of the front panel pc-board)
1. Start current
With trimmer (23) the start current in the position “special 4-stroke”
can be adjusted
Left turn max. corresponds to -50 %,
right turn max. corresponds to + 50 % of the welding current chosen.
2. Final current
With trimmer (22) the final current in the down slope process (special 4-stroke operation)
can be adjusted.
The current is independent of the adjusted welding current -in case of the welding current
is inferior to the adjusted final current, there is no down slope.
3. Down slope time
The down slope time is adjusted by trimmer (21 )
4. Intermission time
Using interval welding the intermission time can be changed by trimmer (24) in the range
0.5s to 2.5s.
14
10 Activation of the fixed TEDAC programs (jobs)
Selecter (3) in position “fixed TEDAC programs (jobs)”
Activation of the welding programs by using the TEDAC slide switch on the TEDAC-torch.
Programs 1-4 correspond to: 1 = green
2 = yellow
3 = orange
4 = red
In this operation mode the variable resistors for the energy (18), the arc length (17) as well as
selector (2) are out of function. The welding process is selected by the fixed program.
Pre-indication of the upper digital read-out:
According to the position of selector (7) welding voltage in V,
wire feed speed in m/min or
thickness material in mm
Pre-indication of the lower digital read-out: welding current in A
The welding process is indicated by a point at the right side of the welding current display ( 11 ):
MIG-MAG no point
PULSE point at the right side
INTERPULSE side point is flashing
10.1 Generating your own TEDAC program
1) Press down button (9) and pull simultaneously the TEDAC-slide switch mounted
on the TEDAC-torch for about 5 s. Herewith you enter the program mode.
2) Press the TEDAC-slide switch on the TEDAC-torch towards the front to select the
individual program point (P1: green, P2: yellow, P3: orange, P4: red).
3) Set selector (2) on the desired welding process (MIG-MAG, PULSE, INTERPULSE).
4) Select the desired arc by the variable resistor ( 18 - energy) and the variable resistor
(17 - arc length).
5) Weld with these parameters and adjust them as requested.
6) Store this setting of these parameters by pulling the TEDAC-slide switch for about 5 s.
The storage is confirmed by the indication by the letters “STO” in the display for about 1 sec.
7) Herewith this program (job) is stored.
8) Proceed in the same way with the three remaining programs.
9) For leaving the program mode, press down button (9) and pull simultaneously the TEDAC-
slide switch mounted on the TEDAC-torch for about 5 s.
15
11 Pulse-Arc Welding Units PU 400 DW and PU 520 DW
11.1 Advantages – Point by point
¾ Compact and clearly arranged housing:
Generator, control panel, control and water cooling system are mounted in one housing.
¾ Rotating mounting of the wire feeder on the welding unit.
The swivelling axis is placed asymmetrically at the rear of the wire feeder and allows a wide
work area. The wire feeder rotates easily to the desired position without kinking the torch lead.
Due to this construction, the movements of the connection cable is reduced to a minimum.
¾ Safe transport due to the locking of the wire feeder. - Connection cables available in different
lengths: Quick and easy change due to clampable and pluggable couplings on both sides.
¾ Gas bottle holder for 10, 20 and 50 I cylinders. Lowered for an easy handling of the
cylinders. Galvanized: no corrosion due to possible frictions.
¾ Large swivel and carriage wheels for an easy handling in the workshop and in the plant. - 4
lifting eyes to transport the welding unit (option).
¾ Reduced electrical consumption in stand-by-operation. - Demand-on switching of the water
pump and ventilator.
¾ High efficiency factor due to a modern electronic.
¾ Special filters avoid radiation.
- tremendous time saving due to reduction of
working hours for cleaning
- high output of wire melting
- long endurance of torch consumables
- extended switch-on time when using machine welding.
¾ Safe, spatter reduced ignition due to a new ignition process controlled by 14
parameters:
- 2 independent ignition pulses
- precise soft start of the wire
- slag droplet on wire removed for re-ignition.
¾ 144 stored welding programs for
- different materials
- different wire diameters
- different protective gases
- Pulse-Arc, MIG/MAG and Interpulse welding.
16
¾ Multiples variations of the pulse parameters:
Manipulation of the arc characteristics and the penetration.
¾ Application of thicker wire diameters compared to MIG/MAG welding.
Savings due to purchase of thicker wire.
¾ Alloy elements are maintained due to
adaption of the pulse parameters when using high alloyed wire.
¾ Structure of the Pulse-Arc welding programs:
Flexible program structure with 35 free programmable
parameters. Perfect ignition due to 13 variable parameters
within the ignition process. 144 different pulse forms
programmable. Generating of different forms of welding
characteristic curves for the welding parameters possible.
¾ New procedure of MIG/MAG short arc welding process
Due to the new technology, already in short arc welding a very
spatter reduced weld is achieved. The range of
the non-desired mixed arc is reduced to a minimum.
¾ Comparison spatters MAG/Pulse-Arc welding:
Spatter emission in relation to the welding current
in percent. The comparison shows the outstanding
results in favour of the Pulse-Arc welding
and the traditional MAG welding using
CO? or mixed gas as protective gas.
11.2 Construction of the housing:
1) Easy to service and to open, all components clearly arranged with easy access.
2) Electronical components are dust protected placed in a separate department.
3) Easy mounting of the connection cable due to clamp-able and pluggable fittings.
4) Efficient cooling of all power components in the air tunnel.
11.3 Locking of the control panel
¾ reduction of the functions to a minimum:
Main switch, LED-displays, gas check, adjusting of the energy and arc length
(both at the wire feeder).
¾ only authorized persons can manipulate the operation modes and programs.
¾ in operation mode "Fixed Programs" the welder can activate 4 different free
programmable welding caracteristic curves at the TEDAC-torch.
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12 Cleaning
IMPORTANT:
!!! Before opening the machine, disconnect it from mains !!!
Open the side covers. Remove dust from all parts of the machine.
Blow away the dust at the pcbs of the inverter withcompressed air –reduced pressure
(appr. 0,5 – 1 bar). We recommend to clean the unit in regular periods.
13 Maintenance and Accident Prevention
The maintenance of the welding machine consists of a regular cleaning and inspection. It depends
on the environment of the working area and the working hours.
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.
ATTENTION: Before opening the welding machine, make sure
that it is disconnected from the mains supply. Wait for
components to be sufficiently cooled down !
Wait until the capacitors are discharged (appr. 3 min.)!
14 Trouble Shooting
14.1 Machine does not operate after switching on the main switch
a) Check main supply
b) Check main fuses
14.2 Machine does not react on the torch switch
a) Problem at the torch switch
b) Check internal fuses
14.3 Machine has no or too low welding current
a) Main relais is not working
b) Bad or no contact at the earth lead
c) Torch hose completely or partially broken
d) Problem with rectifier or IGBT- switches in the machine
e) Only 2 main phases are connected, check main fuses
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