MERKLE TIG 254 AC/DC, TIG 300 DC, TIG 240 DC, TIG 180 DC, TIG 171 AC/DC Operation Manual
...
Operation Manual
TIG Welding Units
Model TIG 254 AC / DC
with MERKLE TCG connector
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 Safety instructions 3
3 Duty cycle 5
4 Instructions to avoid interferences due to electromagnetic influences EMC 5
5 Technical Data: 7
5.1 TIG AC/DC Welding Unit, model TIG 254 AC/DC: 7
5.2 Accessories, water cooling unit, model WK 230 9
6 Start Up 9
6.1 Installation of the Machine 9
6.2 Main Supply 10
6.3 Operation with the unit connected to a generator 10
6.4 Torch connect 10
6.5 Earth Lead (Work Cable) 10
6.6 Electrode holder 10
6.7 Transport 10
7 TIG-Welding Unit TIG 254 AC/DC 11
8 Operation of the Unit 12
9 TIG welding 16
9.1 preparing-values at DC welding 16
9.2 preparing-values at AC- welding 16
10 PARAMETERS 17
11 MMA stick electrode –welding 18
10.4.1 Standard value for the metal arc welding 18
12 Cleaning 19
13 Maintenance and Accident Prevention 19
1
14 Trouble Shooting 19
15 TIG hand welding torch - and spare parts 21
15.1 TIG Hand Welding Torch, Model TH 250 G, gas cooled 21
16 Spare parts and wiring diagram 27
16.1 Spare part list TIG 254 AC/DC 27
16.2 Wiring diagram TIG 254 AC/DC 28
16.3 Spare part list WK 230/300 33
16.4 Wiring diagram WK 230/300 33
17 EU-Conformity Attestation TIG 254 AC/DC 35
18 EU-Conformity Attestation WK 230/300 36
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 welding unit,
model TIG 254 AC-DC
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 welding 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
o welding work may be carried out on containers in which gases, fuels, mineral oils or
similar substances have been stored even if they have been empty for a long time
(risk of explosion). See § 31 of accident prevention regulation BGV D1.
15) Welds which will be subjected to high loads and which need to meet specific safety
requirements may only be carried out by specially trained and qualified welders.
15) Never bring the torch close to your face.
16) In areas at particularly high risk of fire, the welder must obtain a welding permit and have
this on his person throughout the duration of the welding work. On completion of
welding, a fire-guard must be delegated to ensure fire protection.
17) Ventilation measures must be applied in accordance with BGI 553, Section 9.
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 60974-10 / VDE 0544 part 10 regarding electromagnetic compatibility. It is nonetheless the
responsibility of the user to ensure that the welding equipment is installed and operated in
accordance with the manufacturer’s instructions. If electromagnetic interference is detected, it is
the responsibility of the user of the welding equipment to find a solution with the technical
assistance of the manufacturer. In some cases, it may be sufficient simply to ground the welding
current circuit. In other cases, it may be necessary to build a complete shield for the welding
power source and workpiece using the input filters. In all cases, electromagnetic interference
must be reduced to avoid any possible malfunctions.
Note:
For safety reasons, the welding current circuit may or may not be grounded. No
modifications may be made to the grounding without the approval of an expert who is able to
determine whether the changes might increase the risk of accidents, e.g. by allowing parallel
welding current return paths which could destroy the ground conductors of other equipment.
Further instructions are contained in TEC 974-XX "Arc welding equipment – installation and
use".
a) Evaluation of the installation site
Before installing the welding equipment, the user must evaluate potential electromagnetic
problems in the vicinity. The following must be taken into consideration:
Other power cables, control cables, signal and telecommunication cables above, below
and next to the welding equipment
Radio and television transmitters and receivers
Computers and other control devices
The health of people in the vicinity, e.g. use of heart pacemaker and hearing aids
Calibration and measuring equipment
Interference immunity of other devices in the vicinity. The user must ensure the
electromagnetic compatibility of other devices used in the vicinity. This may require
additional safety measures.
b) Procedures to reduce emitted interference
1) Mains supply
Welding equipment is to be connected to the mains in compliance with the
recommendations of the manufacturer. If interference occurs, it may be necessary to take
additional precautions, e.g. filters for the mains connection. Make sure that the power
5
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:
5.1 TIG AC/DC Welding Unit, model TIG 254 AC/DC:
Primary:
Supply: 3 x 400 V
Frequency: 50-60 Hz
cos phi: 0.95
TIG operation:
Open circuit voltage: 70 V
Welding voltage: 10-20 V
Welding current: 5-250 A
Duty cycle 45 %: 250 A (10 min.)
Duty cycle 60 %: 230 A (10 min.)
Duty cycle 100 %: 210 A (40°C)
Prim. cont. power: 5.5 kVA
Prim. cont. current: 8 A
Prim. max. current: 11 A
MMA/stick electrode operation:
Stick electrodes: 1.5-6 mm
Open circuit voltage: 70 V
Welding voltage: 20-30 V
Welding current: 5-250 A
Duty cycle 40 %: 250 A (10 min.)
Duty cycle 60 %: 220 A (10 min.)
Duty cycle 100 %: 200 A (40°C)
Prim. cont. power: 9.7 kVA
Prim. cont. current: 14 A
Prim. max. current: 16 A
Protection class: IP 23 (with filter)
Insulation class: H
Colling: AF
Main switch: 3-phase
Operation modes: 2-stroke, 4-stroke,
4-stroke with 2 currents,
4-stroke with current program,
MMA/stick electrode welding
Selector: current 1, current 2,
time 1, time 2,
down slope, gas post flow time,
AC freuqency,
parameter programming
Setting: continuous at rotary switch
7
Energy control: at the unit, at the torch,
hand remote control, foot pedal
Switch: HF/lift arc
Switch: pulsation ON/OFF
Switch: AC mode/DC mode
Switch: test protection device
Button: gas check with hold function
and timer, parameter selection
Digital display: for current, time and
frequency, with pre-display
and hold function
Current 2: 10-250 % of current 1
Pulsation slow: 0.1-2.5 s
Pulsation fast: 50-800 Hz
Pulse shape: "hard" / "soft"
Down slope time: 0-15 s
Up slope time: 0-2 s
Gas pre-flow time: 0-3 s
Gas post-flow time: 3-25 s
Positv ignition impulse: 0-100 ms
AC balance: ± 90 %
AC frequency: 50-200 Hz
AC curve shape: square or noise reduced
Hotstart time: 0-1.5 s
Hotstart current: 5-250 A
Arc force: max. 250 A
LED green: mains ON,
LED green: welding ON,
LED green: Urms<48 V,
LED yellow: temperature protection,
LED red: failure
Socket: remote control
Power source: IGBT inverter
Ignition: HF ignition generator
Norm: EN 60974-1 "S" / CE
Torch connection: Merkle TCG connector
and 5-pole plug
Torch cooling: gas
option: water
Socket 50 mm²: earth lead
Socket 50 mm²: electrode welding cable
Mains supply cable: 4 x 1.5 mm², 5 m long
with plug 3 x 400 V/ 16 A
Gas hose: 2 m long
8
Connection for water
cooling unit: socket 6-pole (option)
for mains supply and
water pressure control
Handle: on top of the machine
Weight: 39 kg
Dimensions L x W x H: 600 x 300 x 565 mm
Standard accessories:
Earth lead 35 mm², 4 m long 022.1.0401
with plug and earth clamp
Regulator argon/CO2 107.018
standard version
5.2 Accessories, water cooling unit, model WK 230
Technical data:
Power supply: 1 x 400 V / 230 V
Frequency: 50 Hz (60 Hz)
Mains current: 1 A / 1.6 A
Water pump: high efficient pump 230 V
Water prussure: 3.5 bar
Water capacity: 3 l
Transformer: 400 / 230 V
Water pressure switch: integrated
Functions: automatic switch of fan
and water pump
Electr. connection: cable with 6-pole plug
water connection: 2 quick couplings
Weight: 18 kg
Dimensions L x W x H: 530 x 230 x 215 mm
6 Start Up
6.1 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.
9
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 Operation with the unit connected to a generator
Consider the following comments:
The power of the generator must be at least 10% higher than the power of the welding unit.
The generator´s outcoming voltage must be stabilized in the no load voltage mode as well.
Due to possible peaks of the generator when switching ON, the welding unit should be
switched ON afterwards.
6.4 Torch connect
To plug into minus socket (Gas current clutch) torch connection gas current couplers of the
torch and to turn through right solid attract so that protective gas is sealed.
CAUTION: Employing Merkle TIG- torch only originally !
Otherwise assurance claim goes out
6.5 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.
6.6 Electrode holder
Only use electrode holders with a proper insulation and a good contact with the electrode.
6.7 Transport
The plant without larger expenditure can be advanced by their low weight and by the
mounted handle.
The gas bottle must not be attached due to the small device emphasis to the plant.
10
7 TIG-Welding Unit TIG 254 AC/DC
The welding unit TIG 254 AC/DC is based on inverter technique and
are suitable for TIG-welding in AC, DC and for MMA/stick electrode welding. Continuous
setting of the welding current is up to 250 A.
Thanks to their portable, lightweight and compact design, they save space in the workshop and
it are particulary suitable for use at changing locations.
The units can be characterized by numerous features:
• inverter power source with continuous setting of the current 5 -250 A
• low weight: 39 kg only
• 2-stroke, 4-stroke Operation
• two welding currents separately adjustable at the torch
• high frequency (HF) and Lift-arc ignition
• continuous setting of the down slope
• socket for remote control
• gas post-flow adjustable
• digital read out with pre-display and hold-function
• TIG pulsation as a Standard
• Option: water cooling unit WK 230
• stick electrode operation:
1. Arc force:
increasing of the welding current in order
to avoid adherence of the electrode.
2. Hotstart function:
increasing of the start current to
assure a safe ignition.
3. Anti stick function:
In case of adherence of the electrode, the current
is switched off immediately. Reignition after separation
only is possible with a short retardation.
Option: Water cooling unit WK 230
Easy mounting and dismounting of the water cooling unit WK 230 in a few seconds with
electrical pluggable connection.
Generator and water cooling System then form one light and compact unit easy to transport.
Different applications are possible p. ex.:
• welding with a water cooled torch in the workshop,
• using a gas cooled torch on the building site.
11
Loading...