Notice d´utilisation postes de soudure
semiautomatiques MIG/MAG 170 - 230
Gebruiksaanwijzing
Lasapparaat MIG/MAG 170/230
D
Achtung!Lesen Sie diese Anleitung vor der Installation und Inbetriebnahme aufmerksam durch.
GB
Attention!Carefully read through these instructions prior to installation and commissioning.
F
Attention!Prière de lire attentivement la présente notice avant l'installation et la mise en service.
NL
115 117 3671 / D/GB/F/NL /1303 - 5.1
Attentie!Lees deze instructies voor de installatie en ingebruikname aandachtig door.
Contents
1Specifications
2Regulations for the Prevention of Accidents
2.1 Welding Output
3Operation
4Installing the Wire Spool
5Welding Stainless Steel and Aluminium
6Practical Hints for MIG Welding
7Maintenance
8Trouble Shooting
9Spare Parts List and Accessoires
User Responsibility
This machine will perform in conformity with the description contained in the instructions provided.
This machine must be checked periodically. Defective equipment (including service leads) should not be used.
Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should
such repair or replacement become neccessary, it is recommended that such repairs are carried out by qualified
persons approved by the equipment manufacturer or its representative. The user of this machine shall have the
sole responsibility for any malfunction which results from improver use or unauthorized modification from standard
specifications, faulty maintenance, damage or improper repair by anyone other than qualifieded persons approved
by the equipment manufacturer or its representatives.
Read and understand this manual before commissioning your machine!
We reserve the right to change specifications.
GB
Product Liability/Warranty
These welding machines shall only be used as specified. Any other use requires the written consent of Metabo GmbH,
Business Unit Elektra Beckum, P.O.Box 1352, D-49703 Meppen, Germany.
This product carries 2 years (5 years on main transformer and choke) manufacturer warranty under the prevailing legal
provisions, which may vary from country to country. Retain proof of purchase! You are only entitled to claim warranty
against proof of purchase. Please see back cover for manufacturer representative's address nearest you.
The warranty period begins with the date of the original purchase by the end user. Proof of purchase should be retained
and must be presented in the event of a warranty claim. This warranty excludes and does not cover defects, malfunction
and failure caused by natural wear, overload, unreasonable use or failure to provide reasonable and necessary
maintenance.
In case of a defect notify your dealer or Elektra Beckum distributor, who will decide how to handle your claim. Warranty
claims can only be taken care of by your Elektra Beckum dealer or authorized service centre.
1Specifications
MIG/MAGMIG/MAG
170/30 TL170/30 TL Combi
Welding range25 - 160 A25 - 160 A
Open-circuit voltage15.3 - 22 V15.3 - 22 V
No-load voltage19 - 37 V19 - 38 V
Input capacity4.0 kVA3.6/4.0 kVA
Mains 50/60 Hz AC1 ~ 230 V1 ~ 230/2 ~ 400 V
Frequency50-60 Hz50-60 Hz
Welding steps66
Wire diameter0.6 - 0.8 mm0.6 - 0.8 mm
Weldable material0.5 - 5 mm0.5 - 5 mm
Duty cycle (25°c/ 40°C )160 A 30%/20%160 A 30%/20%
100% (25°c/ 40°C )90 A/60A90 A/60A
Mains fuseT 16 AT 16 A
CoolingFF
Protection classIP 21IP 21
Isulation classFF
Welding gun assemblySB 14/2SB 14/2
Dimensions l x w x h840x410x580840x410x580
Weight61 kg62 kg
MIG/MAGMIG/MAGMIG/MAG
180/35 ET200/35 ET230/40 ET
Combi
Welding range25 - 180 A25 - 200 A25 - 230 A
Open-circuit voltage15.3 - 23 V15.3 - 24 V15.3 - 25,5 V
No-load voltage17.5 - 33 V21 - 34 V19 - 34 V
Input capacity3.6/4.6 kVA6 kVA6.5 kVA
Mains 50/60 Hz AC1 ~ 230 V/2 ~ 400 V3 ~ 400 V3 ~ 400 V
Frequency50-60 Hz50-60 Hz50-60 Hz
Welding steps666
Wire diameter0.6 - 0.8 mm1,0 mm0.6 - 1.0 mm
Weldable material0.5 - 6 mm0.5 - 7 mm0.6 - 9 mm
Duty cycle (25°c/ 40°C )180 A 35%/25%200 A 35%725%230 A 40%/30%
100% (25°c/ 40°C )100 A/70A110 A/75A140 A/100A
Mains fuseT 16 AT 16 AT 16 A
CoolingFFF
Protection classIP 21IP 21IP 21
Isulation classFFF
Welding gun assemblySB 15/2SB 15/2SB 25/2
Dimensions l x w x h840x410x580840x410x580840x410x580
Weight68 kg75 kg81HAM kg
StandardScope of delivery:Welding machine with MIG/MAG torch c/w contact tip and gas shroud, pressure
regulator for shielding gas, earth clamp, wire brush and nozzle anti-clogging spray.
delivery:
2Regulations for the Prevention of Accidents
Know the applicable regulations for electric arc welding and strictly adhere to.
Safety Instructions
● Protection against electrical accidents
- Welding cables are to be firmly connected to ensure proper conducting capacity
- Mains cord and welding cables are to be protected against damages.
- Replace damaged mains cords with genuine Elektra Beckum parts only.
- Place welding gun onto insulating backing during short work break.
- For longer breaks switch off machine.
- When welding, wear dry and insulating gloves and shoes.
- For maintenance and repair work disconnect from power mains.
- Screen off work place to protect other persons working nearby against UV rays.
- Welding material having a polluted or contaminated surface may generate toxic fumes. Clean surface before
welding.
- Zinc-plated or galvanized material should not be welded as zinc fumes are highly toxic.
2.1 Welding Output
Box 6Welding process Symbol e.g.:Manual metal arc welding with covered electrodes
Tungsten inert-gas welding
Metal inert and active gas welding including the use of flux cored wire
Selfshielded flux cored arc weldingSubmerged arc weldingSymbol for plasma cuttingSymbol for plasma gouging
Box 7Symbol for welding power sources which are suitable for supplying power to welding operations
carried out in an environment with increased hazard of electric shock (if applicable).Box 8
Welding current symbol e.g.:
Direct currentAlternating current, and additionally the rated frequency in
hertz e.g.: ~50 Hz
Box 9U0... V Rated no-load voltage
a) Arithmetic mean value in case of direct current
b) RMS value in case of alternating current
c) Ur... V Reduced rated no-load voltage in case of a voltage reducing device
d) Us... V Switched rated no-load voltage in case of an a.c. to d.c. switching device
Box 10... A/... V to... A/... V Range of output, rated minimum and maximum welding current and their
corresponding conventional load voltage.
Box 11X Duty cycle (duty factor) symbol.
Box 12I2 Rated welding current symbol.
Box 13U2 Conventional load voltage symbol.
Boxes11a, 11b, 11c ...% Values of the duty cycle (duty factor).
12a, 12b, 12c ... A Values of the rated welding current.
13a, 13b, 13c ... V Values of the conventional load voltage.
These boxes form a table with corresponding values of the three settings:
a)... % duty cycle (duty factor) at the rated maximum welding current;
b)60 % duty cycle (duty factor);
and
b) Welding Output
Box 6Welding process Symbol e.g.:
Manual metal arc welding with covered electrodes
Tungsten inert-gas welding
Metal inert and active gas welding including the use of flux cored wire
Selfshielded flux cored arc welding
Submerged arc welding
Symbol for plasma cutting
Symbol for plasma gouging
Box 7Symbol for welding power sources which are suitable for supplying power to welding operations
carried out in an environment with increased hazard of electric shock (if applicable).
Box 8Welding current symbol e.g.:
Direct current
Alternating current, and additionally the rated frequency in
hertz e.g.: ~50 Hz
Box 9U0... V Rated no-load voltage
a) Arithmetic mean value in case of direct current
b) RMS value in case of alternating current
c) Ur... V Reduced rated no-load voltage in case of a voltage reducing device
d) Us... V Switched rated no-load voltage in case of an a.c. to d.c. switching device
Box 10... A/... V to... A/... V Range of output, rated minimum and maximum welding current and their
corresponding conventional load voltage.
Box 11X Duty cycle (duty factor) symbol.
Box 12I2 Rated welding current symbol.
Box 13U2 Conventional load voltage symbol.
Boxes11a, 11b, 11c ...% Values of the duty cycle (duty factor).
12a, 12b, 12c ... A Values of the rated welding current.
13a, 13b, 13c ... V Values of the conventional load voltage.
These boxes form a table with corresponding values of the three settings:
a)... % duty cycle (duty factor) at the rated maximum welding current;
b)60 % duty cycle (duty factor);
and
c)100 % duty cycle (duty factor) as far as relevant.
Column a)need not be used if the duty cycle (duty factor) for the rated maximum welding
current is 60 % or 100 %.
Column b)need not be used if the duty cycle (duty factor) at the rated maximum welding current is 100 %.
c) Energy input
Box 14Energy input symbol e.g.:
Input supply, number of phases (e.g. l or 3), symbol for
alternating current
and the rated frequency (e.g. 50 Hz or 60 Hz)
Engine
Motor
Belt drive
Box 22IP..Degree of protection, e.g. IP21 or IP23.
Box 23Symbol for protection class II, if applicable.
3Operation
Initiation
Connect cable assembly to central coupling (1). Be sure that collar nut is fully tightened. Plug earth cable into socket
(7) and lock in position.
Place gas sylinder onto rack at rear of machine and secure with chain. Attach gas hose to pressure regulator and
secure with hose clamp provided.
Open gas cylinder valve briefly to clear any foreign matter from it, than attach pressure regulator.
Set regulator to required gas flow rate (approx. 10 - 13 ltr./min. - 2.5 - 3 GPM).
Caution: Do not dismantle the pressure regulator for any reason. It may explode when assembled incorrectly!
1-Phase Machines
These machines come fitted with a Schuko 2-prong
plug with earth contact as standard. For the U. K. and
certain other markets machines are supplied without
a plug on the power cord. Connect to power mains
only by earthed plug and earthed receptacle matchine
your local standard. Mains furse 16 amp time-lag
required.
3-Phase Machines
Three-phase machines are supplied with a CEE 5-pin
plug on the power cord. If a plug matching your local
standard has to be installed, connect only as shown at
right. The yellow/green earth lead must be connected
to the terminal marked .
Wiring diagram for Elektra Beckum
3 phase MIG welding machines
earth lead yellow/green
L1
L2
L3
230 V/ 400 V
Combi Machines
Combi models come with a CEE 3-phase 5 prong plug
fitted to power cord as standard, and an adaptor with
1-phase plug.
If a 3-phase plug matching your local standard outlet
has to be installed, connection has to be made to 2
phases, neutral and earth.
zero/neutal lead blue
earth lead yellow/green
For 380/415 V operation
connect to 2 phases + zero
and earth lead
L1 black
L2 brown
Caution: Have machine connected to power mains by a qualified electrician only!
Neon Control Light
Central coupling KZ 2
for welding gun
Welding step selector
Mains on/off switch
Earth cable socket
4Installing the Wire Spool
4.1 Disconnect from power mains
Place wire spool onto spool carrier so that wire runs off clockwise.
Wire feed regulator
Weld time pot
Dwell time pot
Welding mode selector
(E-models only)
4.2 Wire Feed Set-up
Lever
The feed roller is fitted with four pilot grooves for
wire diameters 0.6/0.8/1.0/1.2 mm.
Central coupling
To adapt the feed roller to the wire size used,
first release the tension roller from the feed roller
by pushing the lever back.
For 1.0 or 1.2 mm wire the corresponding outer
groove is required. Place spacer washer onto
drive shaft, then feed roller so that the required
groove size is in line with the wire intake of the
central goupling. For 0.6 or 0.8 mm wire the
inner grooves are required. Place feed roller
first onto shaft, followed by the spacer washer.
Spacer
Wire Ø 1,0/1,2
After spacer and feed roller have been mounted
as required secure in place with the washer,
serated lock washer and screw. If required, the
two nuts on the central coupling's wire intake
can be loosened and its position centered to the
groove.
Washer
Serrated lock washer
Screw
Feed roller
Spacer
Wire Ø 0,6/0,8
Return the tension roller onto the feed roller an
set to required tension by means of the setting
screw.
4.3 Feeding the Wire into the Torch
Place the wire through the spiral guide tube across the feed roller into the central coupling's wire intake. Bring
tension roller in position and set tension.
Unscrew the gas shroud from the swan neck by turning clockwise, contact tip by turning counter-clockwise. Switch
the machine on, set wire feed speed to lowest speed and press the torch's trigger switch until the wire protrudes
approx. 2.5 cm/1 in. from the swan neck. Replace contact tip and gas shroud.
Please note that all machines as standard fitted for 0.6; 0.8 and 1.0 mm electrode wire. If a wire of a different
diameter is to be used, the contact tip must be exchanged against on of matching size and the feed roller installed
with the corresponding groove size opposite the wire intake.
5Welding Stainless Steel and Aluminium
This MIG welding machine is factory set for welding low-carbon steel. Use a mixed gas (e.g. Ar 99.988 %).
Tension roller
Spiral guide
tube
Setting of Wire Feed Speed
Fine tuning of setting during welding is actually carried out.The feed speed is correct when the arc burns with a steady hum.
To weld aluminium the following components have to be installed on welding gun and torch lead assembly:
- polyamid liner c/w copper spiral liner
- cylindrical gas shroud
- contact tip "A"
- support tube
It is important to have the feed roller set to the correct electrode wire diameter, otherwise the wire will be deformed
resulting in feed problems.
Select electrode wire to match the work piece material (pure aluminium or alloys). Welding aluminium requires a pure
inert gas, such as argon or helium. Set gas flow rate to 10 - 13 ltr/min.
1. Disconnect torch lead assembly from machine and remove electrode wire.
2. Place aluminium wire spool onto spool carrier.
3. Remove liner collet from the torch lead's central coupling and pull steel liner from torch lead assembly.
4. Remove gas shroud and contact tip from torch and replace with cylindrical gas shroud an contact tip "A".
5. Fit polyamid liner into central coupling and push through lead assembly until copper spiral rests firmly against
contact tip. The copper spiral keeps the polyamid liner from becoming too hot and possibly melting.
6. Push liner collet with o-ring into central coupling and secure with collet nut.
7. For polyamid liners of 4.0 mm outer diameter the wire feed unit's steel capillary tube has to be replaced with
a brass support tube. This brass support tube is not required for polyamid liners with 4.7 mm outer diameter.
8. Attach torch lead to central coupling and cut off liner just short of the feed roller. Use a finepitch saw, not pliers.
9. Place remaining polyamid liner between wire spool and feed unit to keep wire from bending and kinking.
10. To thread the aluminium wire into the lead assembly temporarily remove the contact tip.
Thread wire into liner. Set guide roller(s) to match wire diameter and pressure roller(s) to only minimal pressure,
so the wire will not be flattened excessive pressure. Let wire run through lead assembly until it portrudes 2 3 cm from the contact tip.
11. Replace contact tip and gas shroud
Welding aluminium requires a pure inert gas, such as Argon. The gas flow rate should be set to 10 - 13 ltr/min for
up to 200 A. A minium electrode wire diameter of 0.8 - 1.0 mm is recommended.
Stainless Steel Welding
As with aluminium, as pure inert shielding gas is required. Setting of the welding current as with carbon steel.
Prepare torch lead assembly for aluminium welding, but use standard contact tip and conical gas shroud.
Recommended gas flow rate 8 - 12 ltr/min.To prevent a porous weld seam forehand welding is recommended.
For shielding gas both a mixed gas or pure Argon can be used.
Comprising: PA liner 3 m, cylindrical gas shroud SB 15/15, contact tip SB 14-15, 0,8/1,0/1,2, guide tube for PA liner
und assembly instructions.
Aluminium Welding Kit:
Wire ØStock-No.
0.8 - 1,2 mm090 202 7939 with polyamid liner
For shielding gas a mixed gas with a low percentage of CO2 (< 5%) can be used (observe supplier information).
Welding Mode Selector (no. 6)
Symbol
Function
First operation of trigger switch engages continuous welding mode,
second operation disengages
Machines operates as long as trigger switch
is held
Stitch-weld mode
2345678901
2345678901
2345678901
Spot-weld mode
Setting of stitch and spot weld periods by potentiometers (nos. 8 + 9)
t1 = setting of weld time
t2 = setting of dwell time
6Practical Hints for MIG Welding
This distance required between the torch and the workpiece is directly related to the welding current:
●small current=small distance
●high current=greater distance
Too little distance causes excessive wear of the contact tip and gas shroud. Too much distance will not provide
enough gas protection of the welding seam, it becomes porous.
Move the welding gun along the seam in a steady motion, always keeping the same distance between the torch
and workpiece.
Welding may be done either forehand or backhand, in a straight line or, with larger gaps, in a pendulum motion.
MIG welding is suitable for thin plate welding, as well as for welding thicker materials of up to 12 mm.
For thin plate welding we recommend the use of electrode wire of 0.6 mm diameter and a mixed shielding gas.
Welding Preparations
Attach earth clamp to work piece as close as possible to the welding seam (remove rust, paint etc. to ensure good
conducting). Set welding current and wire feed speed with welding step selector and wire feed speed regulator as
required. Make trial runs on scrap material to find correct setting.
6.1 Earth Cable
Connect earth cable plug to Earth Cable Socket on the machine's front panel. Use only genuine Elektra Beckum
parts with recommended cross sections. Structural components, beams, pipes or rails should not be used for earth
conducting, if they are not the actual workpiece. When using welding tables or jigs ensure proper conducting.
6.2 Gas Flow Setting
The correct amount of shielding gas and a steady gas flow at the welding seam are essential to provide sufficient
shielding of the weld pool. Insufficient shielding causes porous welding seams.
Rule of thumb to calculate the shielding gas flow rate required:
Amount of gas in ltr/min = 10 x the electrode wire diameter in mm
Example: Wire diameter 1.0 mm requires a gas flow rate of 10 ltr/min.
Diagram showing the exact gas flow rate required, accounting for different welding current settings
Gas flow rate
in ltr/min
Steel
Gas shroud
diameter in mm
Welding current in A
7Maintenance
The contact tip and gas shroud are the parts most exposed to the radiant heat of the arc and thus are normal
wearing parts. They have to be cleaned regularly of spatters and sprayed with anti-clogging spray.
Execessive built-up of spatters can short-circuit contact tip and gas shroud, ruining both. Spatter built-up inside
the gas shroud also affects the gas flow to the welding seam.
The machine has to be checked in regular intervals for visible damages.
Dust built-up inside the machine can reduce the duty cycle considerably and may even cause a short circuit. Check
regularly and clean if necessary.
Before removing side panel be sure that machine is disconnected from power supply to prevent injury from electric
shock.
8Trouble Shooting
Fault
Irregular wire feedIncorrect tension of tension roller
Brittle or porous welding
seam
Constant gas flowSolenoid valve defective or dirtyCheck, clean or replace
No wire feedTrigger switch or leads in lead ass'y defective
CauseRemedy
Adjust tension
Pilot groove of feed roller and intake nozzle not
aligned
Liner clogged or not correct size for wire
Wire spooled irregularly, rusty or of inferior quality
Wire spool carrier to tight
Feed rollers dirty of worn, groove not matching
wire size
Gas line fittings not tight
Gas cylinder empty
Gas cylinder valve closed
Pressure regulator not working
Solenoid valve not working
Gas shroud or line in lead ass'y clooged
Air draft at weld seam
Workpiece not clean
Wire of inferior quality or unsuitable gas
PCB defective
Fine wire fuse on PCB defective
Align
Check and/or change
Clean or change liner
Change spool
Loosen
Clean or replace
Check fittings
Replace cylinder
Open valve
Check
Check power at solenoid
Clean shroud and spray, blow out gas line
Protect from draft or increase gas flow
Remove rust, grease, paint
Change wire, use suitable gas
Check, replace if necessary
Replace
Replace (2 amp time-lag)
Wire feed speed not
adjustable
Not welding current with
normal working wire feed
Arcing when gas shroud
touches workpiece
Torch becomes excessively hot
No function of machine
Torch under current when
machine is switched OFF
3-phase machine:
excessive spattering with
all welding step setting
3-phase machine:
excessive spattering at a
particular welding step
PCB defectiveReplace
Contactor faulty
Step with faulty
Earth cable not conducting
Short-circuit between contact tip and gas shroudClean shroud, treat with anti-clogging spray or
Contact tip loose or too large for wire diameterTighten tip; replace with correct size tip
Mains fuse/circuit breaker tripped
Contactor sticky or contacts burned
One phase missingCheck contactor for proper function
Step switch defective
Cables between step switch and transformer
loose or broken
Replace
Replace
Correct
nozzle dip (see footnote below).
Reset or replace
Check and replace
Check mains fuses, check power at contactor
terminals (all 3 phases)
Check and replace
Check and replace
Important!
The capacitors of the 1-phase machines need 40 seconds to discharge completely after the machine
is switched off. If the electrode wire makes contact with the workpiece during this period, a short
discharge spark is generated.
KONFORMITÄTSERKLÄRUNGDECLARATION OF CONFORMITY
Wir erklären in alleiniger Verantwortlichkeit, daß dieses Produkt mit den
folgenden Normen übereinstimmt* gemäß den Bestimmungen der
Richtlinien**.
F FRANÇAISNL NEDERLANDS
DECLARATION DE CONFORMITECONFORMITEITSVERKLARING
Nous déclarons, sous notre seule responsabilité, que ce produit est en
conformité avec les normes ou documents normatifs suivants* en vertu des
dispositions des directives **
IT ITALIANOES ESPA
DICHIARAZIONE DI CONFORMITÀ DECLARACION DE CONFORMIDAD
Noi dichiariamo sotto la nostra esclusiva responsabilità che il presente
prodotto è conforme alle seguenti norme*. in conformità con le disposizioni
delle normative **
PT PORTUGU
DECLARAÇÃO DE CONFORMIDADE
Declaramos sob nossa responsabilidade que este produto está de acordo
com as seguintes normas*.de acordo com as directrizes dos regulamentos
**
FIN SUOMINO NORGE
VAATIMUKSENMUKAISUUSVAKUUTUSSAMSVARSERKLÆRING
Vakuutamme, että tämä tuote vastaa seuraavia normeja*.on direktiivien
määräysten mukainen**
SSV SVENSKA
We herewith declare in our sole responsibility that this product complies with
the following standards*
in accordance with the regulations of the undermentioned Directives**
Wij verklaren als enige verantwoordelijke, dat dit product in overeenstemming
is met de volgende normen*
conform de bepalingen van de richtlijnen**
OL
Declaramos bajo nuestra exclusiva responsabilidad, que el presente producto
cumple con las siguientes normas*.de acuerdo a lo dispuesto en las
directrices**
F
KRAN OM ÖVERENSSTÄMMELSE
Vi försäkrar på eget ansvar att denna produkt överensstämmer med följande
standarder*. Enligt bestämmelserna i direktiven**
Vi erklærer under eget ansvar at dette produkt samsvarer med følgende
normer*. henhold til bestemmelsene i direktiv**
DA DANSKPOL POLSKI
OVERENSSTEMMELSESATTESTOŚWIADCZENIE O ZGODNOŚCI
Hermed erklærer vi på eget ansvar, at dette produkt stemmer overens ed
følgende standarder*. iht. bestemmelserne i direktiverne**
EL ΕΛΛHNIKAHU MAGYAR
∆ΗΛΩΣΗ ΑΝΤΙΣΤΟΙΧΕΙΑΣMEGEGYEZŐSÉGI NYILATKOZAT
∆ηλώνουµε µε ιδία ευθύνη ότι το προϊόν αυτό αντιστοιχεί στις ακόλουθες
προδιαγραφές* σύµφωνα µε τις διατάξεις των οδηγιών**
Oświadczamy z pełną odpowiedzialnością, że niniejszy produkt odpowiada
wymogom następujących norm*.według ustaleń wytycznych **
Kizárólagos felelősségünk tudatában ezennel igazoljuk, hogy ez a termék
kielégíti az alábbi szabványokban lefektetett követelményeket*.megfelel az
alábbi irányelvek előírásainak**
MIG/MAG 170/30 TL - MIG/MAG 170/30 TLC
MIG/MAG 180/35 ETC - MIG/MAG 200/35 ET - MIG MAG 230/40 ET