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

Front panel TIG 254 AC/DC

8 Operation of the Unit

1: selector Operation mode

a) TIG-DC /AC-DC weldinq: 2-stroke

1st stroke: after pressing the torch switch the current is switch on

2nd stroke: after releasing the torch switch the current is

decreased to the "final current" according to the

"down slope time" and switched off. The "gas post-

flow time" Starts.

12

b) TIG-DC /AC-DC welding: 4-stroke

1st stroke: after pressing the torch switch and igintion ofthe

arc the "inital current" is activated

2nd stroke: after releasing the torch switch current is increased

to the selected value of "current 1"

3rd stroke: after pressing the torch switch the "down-slope" is
activated. The welding current is reduced to the
"final current" which is active until step 4

4th stroke: the torch switch is released: the "down-slope" is
stopped and the welding is switch off or the "final
current" is switch off. The "gas post-flow time" starts.

If the torch is equipped with two switches, the "current 2" can be activated by pressing the second
switch during the welding process.

c) TIG-DC /AC-DC welding: 4-stroke with current I1 and I2
This Operation mode is similar to the Standard 4-stroke operation. By using a torch with

one torch switch, the welding current is switched from "current 1" to "current 2" and v. v.
by a short touch of the torch switch (less than 0.5 s). If the torch switch is press down

longer than 0.5 s the 3rd stroke is activated ("down slope")

d) TIG-DC /AC-DC welding: 4-stroke with current Programm
This Operation is similar to the 4-stroke Operation. In the 3rd stroke the
current is reduced with the down slope time. If the torch switch is released
the current will return to the pre-selected value 1. By pressing the torch switch
less than 0.5 s the current is switched off immediately.

e) Stick electrode Operation

2: Selector current control

a) control at the weldinq unit

The welding current is adjusted by turning the rotary switch (4) while selector (3)
is in position current I1. The value is displayed on the display (5).

b) control at the var. resistor at the torch

The maximum welding current is adjusted by turning the rotary switch (4) while
selector (3) is in position current I1. The welding current pre-selected by the var. resistor
at the torch is displayed in display (5).

c) control at the hand remote control

This function is identical to b). The electrical connection is made at the 10-pol.
remote control socket. The welding current pre-selected by the var. resistor at the
hand remote control is displayed in display (5).

13

d) control with a foot pedal

This function is identical to b). The electrical connection is made at the 10-pol.
remote control socket. The foot pedal is only working in TIG Operation mode.

3: Selector for rotary switch (4)

Dependend on the position of selector (1) the following values are displayed at
the digital read-out (5):

The LEDs show the unit: A ,s or Hz.

In TIG welding Operation:

- current I1 (5A...250A)
Main welding current.

In DC mode and AC mode (arc shape hard [HAr]) the current 11 is not limited.
In AC mode (arc shape soft [SOF]) the current I1 is limited to 100 A if the AC
frequency is more than 100 Hz.
In AC mode (arc shape sinusodial [Sin]) the current I1 is limited to 225 A at a fixed
frequency of 50 Hz.

- current I2
The current I2 is displayed in A. When the current I1 is changed, the current I2
also changes but remains in the same relation to I1 {10...200).

The seconed welding current I2 can be activated by a torch with two switches, in
4-stroke Operation with two currents or in the pulsation mode. The second current

is only working without a hand or foot remote control.
In case of adherence of the electrode the current is automatically reduced to a
minimum value.

4: Rotary switch

For adjustment of the parameters seicted by selector (3)

5: Digital read out

6: LED green: Hold-function

After the welding process the last value of welding current is

displayed and the LED (6) is on.

7:LEDs

7.1: green: welding ON

welding voltage is at the Output

7.2: green: mains ON

mains switch is switched on.

7.3: yellow: Thermical protection

electronic is too hot. Wait for cooling down of the unit but do not switch it off

14

(fan cooling)

7.4: red: failure

is on when an electronic failure occurs.

8: Buttom GASTEST

a) The buttom is working in 4-stroke mode with a automatic switch off of the

gas after 60 s.

b) In position parameter of selector (3) this buttom is for programming of the

Parameters.

9: Switch HF/Lift-arc
HF ignition: The arc will be started by a high frequency ignition generator. The tungsten

electrode may not touch the work piece at the ignition process.
Lift Arc ignition: Lift arc ignition is need, when TIG welding is performed close to
sensitive electronic devices. Touch down the tungsten electrode to the work piece, press
down the torch trigger and lift the electrode. While the tungsten electrode touches the
work piece a minimum current is activated in order to prevent the electrode from sticking
to the work piece.

10: Switch AC/DC

Depended on work piece the AC (for aluminium) or DC (for mild steel,

stainless steel, copper) mode has to be selected.

Automatic storage of selected values

All values selected with the selector (3) and the rotary switch (4) (current I1, I2, time

t1, t2, etc.) are automatically stored after the welding process is finished. They will be

shown in the display again when the machine is switched off and on again.

11: Potentiometer AC Balance

In AC TIG mode the ratio between positive and nagative AC current can be adjusted at
the potentiometer Balance. The scale on front plate shows the positive and negative ratio
of the welding current. Adjustment to more negative balance will result in a better
penetration, adjustment to more positive balance will result in a better cleaning of the
weld pool but also result in less penetration and vv.

Automatic safty switch off

In TIG Operation the welding voltage is automatically switched off after 2 s, when no

welding current is achived.

ATTENTION:

In TIG mode the welding voltage is also applied to the stick electrode socket. Disconnect
stick electrode cable when welding in TIG mode.

15

9 TIG welding

9.1 preparing-values at DC welding

- standard values for the TIG manual welding in level position of special alloy steels, direct
current minus polarity kind of current of 0,6, - 6 mm material thickness

Mate­rial­thick­nes in
mm

0,6
0,8
1,0
1,5
2,0
2,5
3,0
4,0

6,0

Weld

-form

I
I
I
I
I
I
I
I

I

Seam­distance
in mm

- 20-30 1 1,6 1,0 4 5

- 40 1 1,6 1,0 4 5

- 45 1 1,6 1,0 4 5

- 50 1 1,6 1,6 4-6 6

- 80-100 1 2,4 1,6 6-8 7

- 100-130 1 2,4 1,6 6-8 7

- 140 two sided 2,4 2,4 8 7
V-

shaping.

X-

shaping.

Midle
welding­current

in A

180 1 2,4 3,2 8-10 10

220 2 2,4 3,2 8-10 10

Number
of layers

Welding-

rod

in mm

wolfram­electrode
grey
in mm

Argon­ tip

Argon
welding­ gas
l/min.

9.2 preparing-values at AC- welding

standard values for the TIG manual welding in level position of aluminum, alternating current
kind of current of 1,0, - 6 mm material thickness

Mate­rial­thick­nes in
mm

0,8
1,0
2,0
3,0
4,0
5,0

6,0

Weld

-form

I
I
I
I
V
V

V

Seam­distance
in mm

- 35 1 1,6 1,0 4 5

- 50 1 1,6 1,6 4 5

- 95 1 2,4 2,4 6-8 7

- 140 1 2,4 2,4 8 7

V 185 1 3,2 3,2 8-10 10
V-

shaping..
X­shaping..

Midle
welding­current

in A

235 2 3,2 3,2 8-10 10

300 2 4,0 3,2 8-10 12

Number
of layers

Welding-

rod

in mm

Wolfram

­electrode
red
in mm

Argon­ tip

For blunt seams on one side in normal and overhead-position are the current values around 5
to 10 %, to increase for throat and overlap joints around 10 %. The table values are valid for
fillet welds as before.

Argon
welding­ gas
l/min.

16

10 PARAMETERS

Set selector (3) to position 'PARAMETER'. Select one parameter by pressing the buttom
'GASTEST'. The selected parameter can be adjusted by the rotary switch (4).

The display (5) first shows the paramter's number (for example P1). Then the parameter's

name is shown [tGAS]. After a short time the value is displayed and can be adjusted by turning
the rotary switch.

The parameters are stored when you select any other postion than 'PARAMETER' at the
selector (3)

name on the display parameter

P1 [tGAS]

gas pre flow time

value/range

0-3s

delivery
setting

Os

your
setting

P2 [tUP]

P3 [IStArt]

P4 [lEnd]

P5 [PULS]

P6 [SPEEd]

P7 [tPLUS]

up slope time

initial current

final current

DC pulse shape

- hard

- soft
DC pulsation frequency

- slow(t1,t2:0.1-2.5s)

- fast (t1: 50 - 800 Hz)
(t2: 2-8 to 8-2

timepart I1-I2)

time of positive ignition pulse

in AC mode

0-2s

5 - 250 A

5 - 250 A

[HAr]
[SOF]

[LO]

[Hl]

0…100ms

0.1s

20 A

20 A

[SOF]

[LO]

50Hz

5-5

20ms

P8 [AC]

switching:
AC curve shape - hard

-soft

-sin (low noice

[HAr]
[SOF]

[SIn]

[HAr]

only 50 Hz)

With DC pulse shape set to 'hard' the currents I1 and I2 are switched without any slopes.
In position 'soft' the pulse edges are smoothed for a noise reduction.
In 'fast pulsation' only the 'hard' mode is working.

17

11 MMA stick electrode –welding

To the stick electrode -welding set the rotary switch (1) into the lowest position.

Caution:

Open-circuit voltage fits at the connection sockets "welding electric circuit".

The device has following functions at the stick electrode-welding

 current adjustment (Arc Force):

Increase in current while push the electrode into the welding bath.

 Electrode high start (Hot Start):

To the secure igniting a higher start current appears for short time.

 Anti Stick function:

While sticking the electrode the current is reduced immediately onto the minimum value.
New start after the peeling first with short delay.

10.4.1 Standard value for the metal arc welding

Tuning of the sweat current according to electrode model and diameter. Rule-of-thumb:

Electrode diameter 2,0 2,5 3,25 4,0 5,0 6,0
(mm)
welding current (A) 40-80 60-100 90-150 140-180 170-240 250-300

Approach information, for example polarity, are to be taken from the instruction of the
respective electrodes.

Values on the left page of the selector (3) of above:

-Main current I1: 5 A ... 250 A

-HOTSTART-time: (0..1,5s) attitude at current switch position I2
Hotstart performs only during the metal electrode welding.

-HOTSTART- current: 5 A ... 250 A
Attitude at switch position during t1
Hotstart-current is announced in A.

-ARC-FORCE (current adjustment): 100 % ... 250 %
Attitude at switch position current adjustment t2
Opposes to a threatening celebration burning of the metal electrode with raised welding
current. The Hotstart-current is announced in A. The minimum value for the
current adjustment corresponds to I1.
The maximum value can be 250 % of I1, limited by the maximal current of the plant. The
current adjustment performs only at the stick electrode-welding.

18

Following attitudes are regarded as standard values:

Rutile-electrodes: 120 %

Basic Electrodes: 150 %
Cellulose-electrodes: 250 %

If nevertheless should burn the electrode, the welding current is reduced to a minimum.
An igniting of the electrode is prevented thus.

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 !

14 Trouble Shooting

code
on the LED
display (5)

F01 red: failure too high or too low

F02 red: failure

F03 red: failure

display (7) failure

supply voltage

no open-circuit voltage

no water pressure

flashing

problem

phase missing?
Main fuse not ok?

Main connector no

contact?

Protection circuit in the
generator is activated.

Switch off the unit and
switch it on again after
3s.
check water in the

water cooling unit.

19

code

display (7) failure
on the LED
display (5)

yellow:

thermical

the power electronics are
too hot.

protection

TIG:

no gas

TIG:
no or low high frequency,

switch (9) is set to “HF”

problem

Let unit cool down, LED
(7.3) must go off.

Air circulation ok?

Welding unit extremly
dirty?

Is the fan working?

Duty cycle to high
Check gas hose inside

the machine.

Check the torch.
Check the gas valve.
No gas?

Disconnect stick
electrode welding
cable.

Is the torch hose

completely lying on the
work piece cable?

FUSS FEEt

-running-

TIG:

TIG:

no reaction to the torch
switch

no reaction to the second
torch switch
TIG:
Var. resistor in the torch

is not working

Selector (2) is set to
“foot pedal”

Disconnect remote any
remote control from the

10 pol. socket.

Disconnect any remote
control from the 10 pol.
socket.

Var. resistor in the torch

is not 10 kohm, set
internal jumper to 47
kohm Position.

20

15 TIG hand welding torch - and spare parts

for torch model TH 250 G - with single connection, „Quick TIG System”
or Euro connection:

15.1 TIG Hand Welding Torch, Model TH 250 G, gas cooled

Technical data:

Cooling: gascooled
DC range: 250 A, 40 % ED
AC range: 200 A, 40 % ED
Tungsten electrodes: 1.0 – 3.2 mm ∅
Weight: 240 g

without hose assembly

21

TIG Hand Welding Torch, Model TH 250 G,gas cooled

22

TIG Hand Welding Torch, Model TH 250 G, gas cooled

Pos. Description Part No._

TIG hand welding torch 108.494
model TH 250 G, 4 m
with Merkle TCG connector

TIG hand welding torch 108.496
model TH 250 G, 8 m
with Merkle TCG connector

TIG hand welding torch 108.498
model TH 250 G, 8 m with Merkle
TCG connector and potentiometer

With Euro Connector:

TIG hand welding torch 105.303
model TH 250 G, 4 m
with Euro connector

TIG hand welding torch 105.308
model TH 250 G, 8 m
with Euro connector

TIG hand welding torch 105.310
model TH 250 G, 8 m with Euro
connector and potentiometer

TIG hand welding torch 107.450
model TH 250 G-MAG, 8 m
with MIG/MAG Euro connector
for PU 250/300 K

Standard equipment: 2,4 mm, ceramic 10.0

Spare parts and consumables:
Pos. Description Part No._

3.1 Tungsten-electrode, grey min 10 pcs 013.0.0111

1.0 x 175 mm

3.2 Tungsten-electrode, grey min 10 pcs 013.0.0112

1.6 x 175 mm

3.3 Tungsten-electrode, grey min 10 pcs 013.0.0113

2.4 x 175 mm

3.4 Tungsten-electrode, grey min 10 pcs 013.0.0114

3.2 x 175 mm

23

Pos. Description Part No._

8.1 Back cap "quick TIG" 1.0 mm, long 106.850
TH 170/250 G, TH 450 W

8.2 Back cap "quick TIG" 1.6 mm, long 106.854

TH 170/250 G, TH 450 W

8.3 Back cap "quick TIG" 2.4 mm, long 106.856

TH 170/250 G, TH 450 W

8.4 Back cap "quick TIG" 3.2 mm, long 106.858

TH 170/250 G, TH 450 W

9.1 Back cap "quick TIG" 1.0 mm, short 107.684

TH 170/250 G, TH/TM 450 W

9.2 Back cap "quick TIG" 1.6 mm, short 107.686

TH 170/250 G, TH/TM 450 W

9.3 Back cap "quick TIG" 2.4 mm, short 107.688

TH 170/250 G, TH/TM 450 W

9.4 Back cap "quick TIG" 3.2 mm, short 107.690

TH 170/250 G, TH/TM 450 W
10 Torch neck TH 170/250 G 106.864
11 O ring 9 x 1.5 min 10 pcs 022.1.0704

12.1 Ceramic nozzle 6.5 min 10 pcs 104.260

TH 170/250 G, TH 450 W

12.2 Ceramic nozzle 8.0 min 10 pcs 104.262

TH 170/250 G, TH 450 W

12.3 Ceramic nozzle 10.0 min 10 pcs 104.264

TH 170/250 G, TH 450 W

12.4 Ceramic nozzle 12.5 min 10 pcs 104.266

TH 170/250 G, TH 450 W

12.5 Ceramic nozzle 15.0 min 10 pcs 104.268

TH 170/250 G, TH 450 W

Options for gas lense operation:

13.1 Gas lense 1.6 mm TH 170/250 G, 110.956

TH 450 W

13.2 Gas lense 2.4 mm TH 170/250 G, 110.958

TH 450 W

13.3 Gas lense 3.2 mm TH 170/250 G, 110.960

TH 450 W

14.1 Ceramic nozzle, heavy duty, size 4 013.7.0035

14.2 Ceramic nozzle, heavy duty, size 5 013.7.0036

14.3 Ceramic nozzle, heavy duty, size 6 013.7.0037

14.4 Ceramic nozzle, heavy duty, size 7 013.7.0038

14.5 Ceramic nozzle, heavy duty, size 8 013.7.0039

14.6 Ceramic nozzle, heavy duty, size 10 013.7.0040

14.7 Ceramic nozzle, heavy duty, size 12 013.4.0037

29 Adjustement wheel incl. 108.354

potentiometer for TH 250/450/600 W

24

Pos. Description Part No._

31 Handle TIG torch, right and left 108.368

side (delivered without ball joint)
33 pc board for TIG double button 107.992

switch (for torch with ball joint)
34 Switch button (red) 107.994

for TIG torch with ball joint
35 Handle TIG torch, right and left 107.988

side (delivered without ball joint)
37 Ball joint for TIG torch handle 107.996

gas cooled incl. fixture nut
44 Merkle TCG connector plug 109.554

(gas cooled) incl. rubber housing and 2 o-rings
45 O-ring 8 x 1.6 min 10 pcs 103.544
47 Round plug 5-pole for TIG torch 021.1.0380

(standard)

50.1 Power cable 4 m TH 250 G 106.868

50.2 Power cable 8 m TH 250 G 106.872

50.3 Power cable 8 m TH 250 G-MAG 107.048

51.1 Control cable 3 x 0.5 LiYY min 50 m 107.646

no shield

51.1 Control cable 3 x 0.5 LiYY 107.646

no shield

51.2 Control cable 5 x 0.5 LiYY min 50 m 107.242

no shield

51.2 Control cable 5 x 0.5 LiYY 107.242

no shield
54 Protection hose leather, min 50 m 107.648

22 mm, black
54 Protection hose leather, 107.648

22 mm, black

58.1 Cable assembly 4 m, TH 250 G 106.866

incl. Euro connector,

control cable 3 x 0.5

58.2 Cable assembly 8 m, TH 250 G 106.870

incl. Euro connector,

control cable 3 x 0.5

58.3 Cable assembly 8 m, TH 250 G 106.871

incl. Euro connector,

control cable 3 x 0.5

Cable assembly with Euro connector:

62.1 Brass body for TIG Euro connector 013.4.0048

incl. nut 5/8"

62.2 Brass body for MIG Euro connector 025.1.1401

incl. nut 5/8"
63 Euro adapter nut 025.1.0300

25

Pos. Description Part No._

64.1 Kinking protection at machine side 013.4.0049

TIG Euro connector (set 3 pieces)

64.2 Kinking protection at machine side 025.1.1300

MIG Euro connector (set 3 pieces)
65 Round plug 5-pole for TIG torch 021.1.0380

(standard)

66.1 Cable assembly 4 m, TH 250 G 108.504

incl. Euro connector,

control cable 3 x 0.5

66.2 Cable assembly 8 m, TH 250 G 108.506

incl. Euro connector, control cable 3 x 0.5

66.3 Cable assembly 8 m, TH 250 G 108.507

for torch with potentiometer, incl. Euro connector,

control cable 5 x 0.5

66.4 Cable assembly 8 m, TH 250 G-MAG 107.047

incl. Euro connector, control cable 3 x 0.5

26

16 Spare parts and wiring diagram

16.1 Spare part list TIG 254 AC/DC

electr. description part no.

-A1 pc-board ME-I2-PL-1.0 / Inverter-primary complete 00300155

-A2 pc-board ME-EMV-4.0 102301

-A3 pc-board ME-I2-SD-1.3 00300157

-A4 Platine ME-I2-RE-1.1 00300156

-A5 pc-board ME-I2-SG-1.1 / Sekundary rectifier complete 00300153

-A6 LEM-current converter 01001615

-A7 ignition generator SIG 8.71 02011610

-A8 pc-board ME-TIG-3.3 00300183

-A9 pc-board ME-BT-2.1 00300184

-A10 pc-board ME-TF-3.1 00300185

-A11 pc-board ME-TFAC-3.1 00300190

-A12 pc-board ME-I2-WE-1.2 102503

-A13 pc-board ME-I2-WE-1.2 102503

-A14 pc-board ME-UESW-4 00300007

-A15 pc-board ME-I-WS-1.1 00300005

-A16 pc-board ME-SYNC-1.1 (Option two side welding) 00102603

-F1 fuse 4 A slow 6,3x32 mm 00301251

-F2 fuse 4 A slow 6,3x32 mm 00301251

-F3 fuse 1 A slow 5x20 mm 00301212

-F4 Fuse 10 A slow 5x20 00301199

-F5 fuse 1 A slow 5x20 mm 00301212

-F6 temperatur switch 80°C opener 00100406

-K1 relais 48V/AC (Option automatic welding)) 01001961
relaissoccet (Option automatic welding) 01001962

-L1 choke 02011668

-L2 HF - choke 02011670

-M1 fan 230V/AC 00101323

-M2 fan 230V/AC 00101323

-Q1 main switch 00100020

-R1

-R2

-R3

-R4

-R5

resistor 6,8 Ω-50W
resistor 6,8 Ω-50W
NTC 100 kΩ in transformer
potentiometer 10 kΩ balance
resistor 6,8 Ω-50W

03004587
03004587

00100502
03004587

27

electr. description part no.

-R6

-R9

-R10

resistor 6,8 Ω-50W
NTC 47 kΩ on cooler IGBT
resistor 2,2 kΩ-9W

03004587
01001933
03004586

-S1 selector HF-lift arc 00300900

-S2 selector pulsation on-off 00300900

-S3 selector AC/AC 00300900

-S4 selector (Option machine welding) 00300900

-T1 main transformer with ferrit core 00101980

-T2 control transformer 00300243

-T3 current converter 02011124

-T4 current converter 02011124

-X1 tcg connector consist from:
socket 35/50 mm

2

00101101

nipple 110098

-X4 socket 10-pol remote control (option) 02110382
plug (accessories) 02110383
srenght member (accessories) 02110388

-X5 connector 5-pol. body 02110394

-X6 connector 6-pol. body (Option water cooler)) 01500101
connector 6-pol. plug (Option water cooler) 01500103

-X7 connector 3-pol. body 00101009
(Option welding two side on)

-Y1 valve 42V/AC 00201602

-Z1 protection 00300330

-Z2 protection 00300330

crimpcontact (accessories) 01600140

16.2 Wiring diagram TIG 254 AC/DC

28

=

SQ

+

1

Blatt

Bl.

4

+SQ-A3-X10/4.8

560V

20kHz

560V

20kHz

Erdungsschraube

-T3

PE

-T1

Trafo

rectifier

70V70V

0V

Gleichrichter/

+SQ-A5:~/2.2

-R3

-F6

bl

rt

+SQ-L1/2.2

bl

rt

or-sw

+SQ-T2:w8-0V/4.5

+SQ-A5:~/2.2

or-sw

+SQ-T2:w8-9V/4.5

+SQ-T2:w2-9V/4.5

vio-ws

or-ws

rt-sw

+SQ-T2:230V/4.5

+SQ-T2:w2-0V/4.5

+SQ-A4-X3:1/1.1

blswbl

+SQ-A12-X1:1/2.5

+SQ-A15-X2:4/2.3

2

1

1234567

4321

3 421

X3

+SQ-A3-X8:6/4.8

6

5

+SQ-A3-X8:5/4.8

ge

ge

8

7

8

+SQ-A12-X2:2/2.5

4

3

X4

-A14

ME-UESW-4

+SQ-A8-X5:6/4.4

+SQ-A8-X5:5/4.4

4

3

2

1

123

X5

U<48V

gn

4

+SQ-T4/2.7

+SQ-T4/2.7

bl

rt

2

1

1

X2

I>0

rt

Zeichnungsnr.

Projektbez.

Auftragsnr.

TIG254AC/DC TCG-Anschluß

2

Schweißstromkreis

3PH-400V/50-60Hz/PE

Erdungs-

schraube

PE

1 2 3 4 5 6 7 8

L1 L2 L3

L1 L2 L3

-Q1

1

rt

Trafo

Primär

UET

26

X1

1

Trafo

Primär

X6 X5

6

L1 L2 L3

T1 T2 T3

1234

rt

X7 X3

X8

X2

1

6

16 1 1234

PE

4 3 2 14 3 2 1

bl

rt

ME-EMV-4.0

L1´L2´L3´

begrenzung

Primärstrom-

bl

sw

-M2

-M1

+

NTC 47k IGBT

M

PE

M

PE

L1L2L3

Lüfter

bl

-

-A1

N

+SQ-T2:230V/4.5

+SQ-T2:400V/4.5

+SQ-T2:0V/4.5

8 turns

ferrit ring

8 Windungen/

Ferritring mit

bl

-- -

bl

ME-I2-PL-1.0

bl

+OP1-X6:2/4.3

+SQ-A14-X3:4/1.6

+SQ-A13-X2:1/2.7

sw

bl

bl

21

54321

bl

+SQ-T2:w4-42V/4.5

ws-bn

ge-sw

5

4

3

2

1

1234567

gn

rt

230V 400V

gn

1 21 2 3 4 5

Lad. Wid

fan

fan

Lüfter/

rt

X4

X3

Lüfter/

-A4

ME-I2-RE-1.1

-Y1

7

6

ge

gas valve

Gasventil/

8

8

rt

I>0/ext.

X2

bn-gn

gas valve

Gasventil /

X1

rt

verz.

116

+SQ-T2:w4-0V/4.5

+SQ-A3-X2/4.6

Merkle

Schweißanlagen-Technik GmbH

Industriestraße 3

D - 89359 Kötz

Telefon [phone] - 0

Name

Konrad

Datum

12.01.00

gez.

Name

Datum

Änderung

c

Telefax 08221 - 32596

Siegner

22.02.00

gepr.

05.07.04

dab

Plotdatum:

UEI

6 6

-A2

Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet

Elektrode

stick electrode

-

+SQ-A8-X7:4/4.4

+SQ-A8-X7:8/4.4

sw-gn

-X3

rs

Werkstück

work piece

+SQ-A14-X2:1/1.6

+SQ-A14-X2:2/1.6

rt

bl

+

-T4

-X2

+SQ-A14-X4:3/1.6

+SQ-A3-X7:1/4.7

bl

bl

-Z2

+SQ-A3-X7:4/4.7

+SQ-A14-X4:1/1.6

rt

rt

rt

bl

sw

2

Bl.

SQ

=

+

Blatt

4

1

2

2

1

X1

X2X4X5

~

-A13

1

2

1

2

X6

Zeichnungsnr.

42V~42V~

T70
T0

D0

-A7

ignition generator

Zündgerät SIG 8.71/

DB

-Z1

Wicklung HF-Drossel

Ferritkern

-L2

-R10

DB

HF-Drossel L1 im

Inverter Draufsicht

D0

-

+

31

rt

bl

12 21 21

X3

2 1 1 2 1 2

1

16

ME-I2-WE-1.1

C

C

-V3

31

2 4

A

A

NTCNTC

-V4

2 4

ME-I2-RC-1.0

B

B

Projektbez.

Auftragsnr.

TIG254AC/DC TCG-Anschluß

-R6 -R7

-A18

-R9 -R8

-R1 -R2

rt

sw

1

2

2

1

bl

X1

X2X4X5

~

-

+

12 21 21

X3

2 1 1 2 1 2

1

-V5 -V6

-A12

-V1

31

2 4

A

16

-R5

1

2

1

2

X6

NTCNTC

ME-I2-WE-1.1

C

-V2

31

2 4

ME-I2-RC-1.0

B

Schweißtromkreis

Merkle

Schweißanlagen-Technik GmbH

Industriestraße 3

D - 89359 Kötz

Telefon [phone] - 0

Telefax 08221 - 32596

-A17

bl

1 2 3 4 5 6 7 8

rt

gn

ge

+SQ-A3-X4:2/4.7

+SQ-A3-X4:3/4.7

+SQ-A3-X4:4/4.7

+SQ-A3-X4:1/4.7

-L1

+SQ-T1:0V/1.6

4321

2 3 41

-A6

~

ME-I2-SG-1.1

+SQ-T1:70V/1.6

+

~

+SQ-T1:70V/1.6

-A5

bl

sw

+SQ-A3-X5/4.6

+SQ-A4-X3:4/1.1

+SQ-A14-X3:4/1.6

3

2

1

123

X2

ME-I2-WS-1.0

-A15

101

X1

UETWR

over temp

4

4

+

-

16 16

rtrtgn

X3 X4

1 1

Name

Konrad

Datum

12.01.00

gez.

Name

Datum

Siegner

22.02.00

gepr.

05.07.04

Änderung

c

dab

Plotdatum:

Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet

+SQ-A8-X4/4.3

PARAMETER

ABSENKUNG

downslope

GASNACHSTRÖMUNG

gas post flow

AC FREQUENZ

Schweissen ein

welding on

frequency

gn

NETZ/

main

Übertemperatur/

overtemp.

gn

ge

Störung/

failure

rt

Balance

E

-R4

3

Bl.

SQ

=

+

Blatt

4

DC

6

A

S

4

AC

L2L1L5 L4 L3

-A11

5

-S3

S Test

ME-TFAC-3.1

Zeichnungsnr.

Projektbez.

Auftragsnr.

TIG254AC/DC TCG-Anschluß

1 26

X1

STROM I1

A

current

current

STROM I2

ZEIT t1

s

time

Hz

time

ZEIT t2

ME-TF-3.1

E AS

I1

I1

I1

I1

X2

10 1

6

5

4

-S2

X1

URMS<48V

16 1

Frontplatte

Puls

3

2

1

-S1

Merkle

Schweißanlagen-Technik GmbH

Industriestraße 3

D - 89359 Kötz

Telefon [phone] - 0

Telefax 08221 - 32596

HF

Name

Konrad

Siegner

Gastest

gas test

Datum

12.01.00

gez.

Name

Datum

Änderung

22.02.00

gepr.

05.07.04

c

dab

Plotdatum:

HOLD

gn

-A10

+I2

1 2 3 4 5 6 7 8

Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet

bl-rt

bl-gn

w9-0V

w9-18V

0,5A

+SQ-F6/1.5

+SQ-A1-X7:2/1.3

ge-rt

ge-ws

gn-sw

or-sw

vio-ws

w6-0V

w7-9V

w7-0V

w8-9V

w8-0V

0,5A

0,5A

bn-sw

ws-bl

w5-0V

w6-18V

0,5A

+SQ-Y1/1.3

+SQ-A4-X1:5/1.2

bl-ws

ws-br

br-gn

w5-18V

1A

w4-0V

0,5A

0,5A

+OP2-A16-X2:6/4.3

+OP2-A16-X2:5/4.3

w3-37V

w4-42V

w3-0V

3A

-F5

-F4

10A

ws-br

br-gn

bl-rt
bl-gn

bn-sw
bl-ws

blau

gelb

grün

rot

+SQ-A6-X1:4/2.3

+SQ-A6-X1:3/2.3

+SQ-A6-X1:2/2.3

+SQ-A6-X1:1/2.3

bl

rt

+SQ-A15-X1/2.2

+SQ-A13-X1:1/2.7

+SQ-A13-X2:2/2.7

4

Bl.

SQ

=

+

Blatt

4

6

5

4

3

2

1

+SQ-A10-X1/3.5

+SQ-A1-X1/1.3

12345

-A3

43214321

X4X7

rt

ge

Idyn

21 3 4 1 2 3 4101

gertrt

Störung

Übertemp.

over temp.

X5

10 pol.

34

6

X8

gn

Istat

gn

I>0

Start

failure

ME-I2-SD-1.3

X1

116 1

X10

26

X2

1

ge

ge

+SQ-A4-X2/1.1

Zeichnungsnr.

Projektbez.

Auftragsnr.

TIG254AC/DC TCG-Anschluß

4A

-F1

400V0V230V

br

+SQ-Q1:T2/1.1

-X4

1 2 3 4 5 6 7 8

E A

1A

-F3

F1

sw

sw

+SQ-A4-X3:4/1.1

+SQ-A14-X3:1/1.6

ABCDE

S

4A

-F2

F2

bl

bl

+SQ-Q1:T1/1.1

+SQ-A4-X3:1/1.1

sw-ws

sw-rt

sw-gn

gn

Ferritring 6 Wdg.

ferritring 6 turns

FT

Fußfernregler/

foot remote control

-T2

0,5A

w2-9V

w2-0V

or-ws

rt-sw

Option: Wasserkühlgerätanschluß/

+SQ-A1-X3:2/1.4

+SQ-A1-X3:1/1.4

ge

7

8

9

10

7

8

9

10

-A9

4

bl

br

Erdungs-

schraube

12345

connection for watercooling unit

or br

rs

vio

3

4

5

6

3

4

5

6

X2

-X6

+OP1

ws ws

bn

1

2

1

2

6

10

987654321

E

ME-BT-2.1

X1

1

2

3

bn

vio

-X5

4

1 2 3

432

1

ws

br-gn

+SQ-A7:42V/AC/2.6

rs

5

4

3

2

1

1234567

X7

WD

gn

KG

gn

gn

X6

JP

123

P1

1 2 3 4 5 6 7 8 9 10

A

S

or

oder/

BT2

torch switch 2

BT1

torch switch 1

ge-ws

gn-sw

ws-br

6

WP

ws-bl

+SQ-A7:42V/AC/2.6

gn

sw-gn

1

8

7

8

HF

rt

EL

ge

4

567

8

3

2

12345

ME-TIG-3.3

Brennerpoti/torch poti

or with torch poti

torch with 2 button

oder mit Brennerpoti/

Brenner mit Doppeltaster

+SQ-A14-X5:1/1.6

+SQ-A14-X5:2/1.6

ge-rt

gn

gn

6

5

4

6

X5

10

-A8

X2

654321

X2

+OP2

-A16

1 2 3 4 5 6

Doppelseitiges

+SQ-T2:w3-0V/4.5

+SQ-T2:w3-37V/4.5

+SQ-A14-X4:8/1.6

1

243

X1

X3

P2

FUSS

ge

X4

BT1

ME-SYNC-1.0

gn

3

2

1

-S4

+OP2

Schweißen ein/

welding two side on

+SQ-A14-X4:7/1.6

134126

Merkle

Schweißanlagen-Technik GmbH

Name

Datum

3

2

1

option: welding two sides

-X7

+OP2

+

-

Testkabel Synchronisation

Name

Option: Doppelseitiges Schweissen/

-

Datum

+

Änderung

Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet

Steuerung

Industriestraße 3

D - 89359 Kötz

Telefon [phone] - 0

Telefax 08221 - 32596

Konrad

Siegner

12.01.00

22.02.00

gez.

gepr.

05.07.04

c

dab

Plotdatum:

16.3 Spare part list WK 230/300

el. abbr. description part no.

-A1 pc-board ME-WP-1.0 00300187

-F1 fuse 2,5 A, slow 6,3x32 00301253

-F2 fuse 2,5 A, slow 6,3x32 00301253

-F3 membran switch0,5 bar 00400204

-F4 overcurrent switch 1,4 A 00300320

-M1 waterpump 230V 50Hz 0,12 kW 00400530

-M2 fan 230V/AC 00101323

-M3 fan 230V/AC 00101323

-T1 contol transformer EI 84/b prim.400V/sec.230V 00101695

-W1 kable 7x1,5mm² 00700600

-X1 socket 6-pol. 01500102
cultivation holder 6-pol. (accessories) 01500100

16.4 Wiring diagram WK 230/300

33

M3

M

LüfterLüfter

=

+

1

Blatt

Bl.

1

0V

0V

230V

400V

F2

F1

2,5At

2,5At

PE

T1

F3

PE

M2

M

Zeichnungsnr.

Projektbez.

Auftragsnr.

WK230-300

4

3

2

1

12345

PE

F4

5

X3

br

bl

M1

schw

M

Pumpe

PE

A1

Stromlaufplan

ME-WP-1.0

123

X2

123

P

Merkle

Schweißanlagen-Technik GmbH

Industriestraße 3

D - 89359 Kötz

Telefon [phone] - 0

Telefax 08221 - 32596

Erdungsschraube

Name

Konrad

Siegner

1

2

3

4

5

6

ge-gn

Datum

W1

.1.1.1.1.1

STROMPFAD

400V IN

400V IN

+60VWD230V IN

1 2 3 4 5 6 7 8

1

2

3

4

5X16

Rel.

PE

X1

1

PIN-NR.

23456

.1

Stifteinsatz 6 pol.

Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet

13.09.99

gez.

Name

Datum

Änderung

11.1199

gepr.

13.06.02

c

dab

Plotdatum:

17 EU-Conformity Attestation TIG 254 AC/DC

EU – Conformity Attestation

Description of the unit: TIG Welding Unit

Model: TIG 254 AC/DC

The above mentionned unit complies with the following European Regulations:

EU-Low Voltage Regulation 73/23/EWG
EU-Electromagnetic Compatibility 89/336/EWG

In case of any modifications, incorrect repairs not exclusively authorized by Merkle, this
attestation looses its valdity.

Applied norms EN 60974 - 1 / IEC 974 - 1 / VDE 0544 part 1

EN 60204 - 1 / IEC 204 - 1 / VDE 0113 part 1

EN 60974-10 / VDE 0544 part 10

Kötz, April 14th, 2004
Wilhelm Merkle, Generalmanager

Merkle Schweissanlagen-Technik GmbH

35

18 EU-Conformity Attestation WK 230/300

EU – Conformity Attestation

Description of the unit: Watercooler Unit

Model: WK 230 / 300

The above mentionned unit complies with the following European Regulations:

EU-Low Voltage Regulation 73/23/EWG
EU-Electromagnetic Compatibility 89/336/EWG

In case of any modifications, incorrect repairs not exclusively authorized by Merkle, this
attestation looses its valdity.

Applied norms EN 60974 - 1 / IEC 974 - 1 / VDE 0544 part 1

EN 60204 - 1 / IEC 204 - 1 / VDE 0113 part 1

EN 60974-10 / VDE 0544 part 10

Kötz, April 14th, 2004
Wilhelm Merkle, Generalmanager

Merkle Schweissanlagen-Technik GmbH

36

Notes:

37

38

M E R K L E

Schweissanlagen-Technik GmbH

MERKLE
Schweissanlagen-Technik GmbH
Industriestrasse 3
D-89359 Koetz,

Germany

Tel.: ++49-8221-915-0
Fax: ++49-8221-915-40
www.merkle.de

3. Edition 2004 September 07th. 2004

Technical changes reserved

39