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EWM HIGHTEC WELDING GmbH Dr.-Günter - Henle - Straße 8; D-56271 Mündersbach Phone: +49 (0)2680.181-0;

EWM HIGHTEC WELDING GmbH Dr.-Günter - Henle - Straße 8; D-56271 Mündersbach Phone: +49 (0)2680.181-0; Fax: +49 (0)2680.181-244

Internet: www.ewm.de ; E-mail: info@ewm.de

Operating instructions

GB
GB
www.ewm.de ; E-mail: info@ewm.de Operating instructions GB integral inverter MIG/MAG Welding Machines from 300A to

integral

inverter

MIG/MAG Welding Machines from 300A to 500A

MIG/MAG pulse welding MIG/MAG standard welding, and TIG welding with HF or Liftarc ignition for MMA welding,

with control system: integral MIG PROGRESS

integral

inverter

integral

inverter

integral

inverter

integral

inverter

integral

inverter

integral

inverter

MIG 300

MIG 300 puls , MIG/TIG 450 puls MIG/TIG 500 puls MIG 450 puls

MIG 500 puls

puls

compact ,

s MIG 450 p u l s MIG 500 p u l s puls compact ,

N. B. These operating instructions must be read before commissioning. Failure to do so may be dangerous. Machines may only be operated by personnel who are familiar with the appropriate safety regulations.s MIG 450 p u l s MIG 500 p u l s puls compact ,

who are familiar with the appropriate safety regulations. The machines bear the conformity mark - and

The machines bear the conformity mark - and thus comply with the

EC Low Voltage Guideline (73/23/EEC) EC EMV Guideline (89/336/EEC)

(The CE Mark is only required in EC member states)

In compliance with VDE 0544 (EN 60974-1), the machines can be used in environments with an increased electrical hazard. an increased electrical hazard.

2000

We reserve the right to make amendments.

Art. No.: 099-004704-EWM01

Revised: 30.08.2000

EG - Konformit ä tserkl ä rung
EG - Konformit ä tserkl ä rung

EG - Konformitätserklärung

Originaldokument

bei!

each Gerät

jedem

liegt

EU - conformity declaration

Déclaration de Conformidité de U.E.

Name des Herstellers:

Name of manufacturer:

Nom du fabricant:

Anschrift des Herstellers:

Address of manufacturer:

Adresse du fabricant:

EWM HIGHTEC WELDING GmbH

(nachfolgend EWM genannt)

(In the following called EWM)

(nommé par la suite EWM)

Dr.- Günter - Henle - Straße 8

D - 56271 Mündersbach – Germany

info@ewm.de

 

Hiermit erklären wir, daß das nachstehend bezeichnete Gerät in seiner Konzeption und Bauart sowie in der von uns in Verkehr ge- brachten Ausführung den grundlegenden Sicherheitsanforderungen der unten genannten EG- Richtlinien entspricht. Im Falle von unbefugten Veränderungen, unsachgemäßen Reparaturen und / oder unerlaubten Umbauten, die nicht ausdrücklich von EWM autorisiert sind, verliert diese Erklärung ihre Gültigkeit.

document

We herewith declare that the machine described

below meets the standard safety regulations of the

EU- guidelines mentionned below in its conception

and construction, as well as in the design put into

circulation by us. In case of unauthorized changes,

improper repairs and / or unauthorized

modifications, which have not been expressly

allowed by EWM, this declaration will lose its

validity.

machine!

Par la présente, nous déclarons que la conception

et la construction ainsi que le modéle, mis sur le

marché par nous, de l´appareil décrit ci - dessous

correspondent aux directives fondamentales de

sécurité de la U.E. mentionnées ci- dessous. En cas

de changements non autorisés, de réparations

inadiquates et / ou de modifications prohibeés, qui

n´ont pas été autorisés expressément par EWM,

cette déclaration devient caduque.

Original

with

Gerätebezeichnung:

Description of the machine:

Déscription de la machine:

 

Gerätetyp:

 

is enclosed

Type of machine:

Type de machine:

Artikelnummer EWM:

Article number:

Numéro d´article

 
 

Seriennummer:

joint à toute original

machine!

est Document

Serial number:

Numéro de série:

Optionen:

Options:

Options:

Zutreffende EG - Richtlinien:

Applicable EU - guidelines:

Directives de la U.E. applicables:

Angewandte harmonisierte Normen:

Used co-ordinated norms:

Normes harmonisées appliquées:

keine

none

aucune

EG - Niederspannungsrichtlinie (73/23/EWG)

EU - low voltage guideline

Directive de la U.E. pour basses tensions

EG- EMV- Richtlinie (89/336/EWG)

EU- EMC guideline

U.E.- EMC directive

EN 60974 / IEC 60974 / VDE 0544

EN 50199 / VDE 0544 Teil 206

 

Hersteller - Unterschrift:

Hersteller - Unterschrift:

Signature of manufacturer:

Signature du fabricant:

Michael Szczesny ,

Geschäftsführer

 

managing director

gérant

05.2000

Table of Contents

Page

Safety instructions

1 About this machine manufactured in inverter technology

1.1 Advantages of inverter Technology and the integral PROCESS

1.2 Integral welding process

1.3 General description of the machine

1.4 integral control systems

1.4.1 integral MIG, integral MIG PROGRESS 4

1.4.2 integral MIG PROGRESS

1.5 Area of application

2 Transport and Installation Notes on the use of these operating instructions

3 Technical data

integral

inverter

3.1 MIG series,

integral

inverter

3.2 MIG/TIG series

3.3 WF case integral DRIVE 4/4S, integral DRIVE 4T, integral DRIVE 4D

4 Description of the System Components

4.1 System overview

4.2 The welding current sources

4.2.1 MIG 300 puls and

integral

inverter

integral

inverter

MIG 300

puls

compact

4.2.2 MIG 450 puls ,

4.2.3 MIG/TIG 450 puls and

integral

inverter

integral

inverter

MIG 500 puls

integral

inverter

integral

inverter

MIG/TIG 500 puls

4.3 The wire feed cases

4.3.1 WF case integral DRIVE 4

4.3.2 WF twin case integral DRIVE 4 D

4.4 integral MIG PROGRESS Controller

4.4.1 Visible operating elements

4.4.2 Additional operating elements which arenot directly visible (flap X)

4.5 The remote controls

4.5.1 Manual remote control integral C10

4.5.2 Manual remote controls integral C20, C30, C40, superPuls SP10, SP11

4.6 The interfaces

4.6.1 Functional description and pin assignment of the interface for mechanised welding

4.6.2 Robot interface RINT 2 (option)

4.6.3 Documentation interface PC INT 1 (option)

Safety/1

1/1

1/1

1/2

1/4

1/5

1/5

1/6

1/6

2/1

2/2

3/1

3/1

3/2

3/2

4/1

4/1

4/2

4/2

4/6

4/8

4/12

4/12

4/13

4/15

4/16

4/18

4/20

4/20

4/20

4/21

4/21

4/22

4/22

Table of Contents

Page

5

Description of Controller integral MIG PROGRESS

5/1

5.1 General

5/1

5.2 Welding parameter selection and adjustment facilities

5/2

5.2.1 Definition of MIG/MAG welding tasks

5/2

5.2.2 Selection of MIG/MAG welding tasks

5/2

5.3 Selection of TIG and MMA welding

5/3

5.4 Operating modes, non latched and latched

5/3

5.5 Storing and retrieving selections

5/3

5.6 Selection: viewing welding data on the LC display

5/3

5.6.1 Viewing nominal values

5/4

5.6.2 Viewing actual values during and after welding

5/4

5.7 Adjusting the working point (welding energy)

5/4

5.7.1 Adjusting the MIG/MAG working point

5/4

5.7.2 Working point adjustment by the wire feed speed

5/5

5.7.3 Working point adjustment by the material thickness

5/6

5.7.4 Setting of the adjustment of the arc length correction

5/6

5.7.5 Setting the welding current for TIG and MMA welding

5/6

5.8 Key-operated switch

5/7

5.9 Selection and adjustment of further welding parameters

5/7

5.9.1

Adjusting the welding parameters

5/7

5.9.2

Gas pre-flow time

5/7

5.9.3

Gas post-flow time

5/8

5.9.4

Wire burn-back

5/8

5.9.5

WFmin (reduced working point)

5/8

5.9.6

Switching the down-slope on/off

5/8

5.9.7

Working point adjustment by the wire feed speed on the keyboard

5/9

5.9.8

Setting the correction of the arc length on the keyboard

5/9

5.9.9

Adjusting the welding current for TIG and electrode welding on the keyboard

5/9

5.10

E1 and E2, freely programmable program spaces

5/10

5.10.1

Calling E1 / E2

5/10

5.10.2

Exiting E1 / E2

5/10

5.10.3

SECURE MODE, storing the entries

5/10

5.10.4

EXPERT MODE, changing the basic welding parameters

5/11

5.10.5

NORMAL MODE, changing the basic welding parameters

5/12

5.10.6

EXPERT MODE, changing the language

5/13

5.11

Operating state "Ready for welding"

5/13

5.11.1

No-power gas test and inching the wire electrode

5/14

Table of Contents

Page

5.12

Monitoring functions

5.12.1

Detection of the connected components

5.13

Error messages

5.14

Function sequence, operating modes

5.14.1

Function sequence MIG standard and pulse non latched

5.14.2

Function sequence MIG standard and pulse latched

5.14.3

Function sequence, operating mode TIG

4.14.4

Function sequence TIG non latched with Liftarc

5.14.5

Function sequence TIG latched with Liftarc

5.14.6

Function sequence, MMA mode

6 Summary of instructions

6.1 The shortest way to MIG/MAG welding

6.1.1 Adjusting the welding parameters

6.1.2 Adjusting the working point

6.1.3 Summary of instructions for additionally adjustable welding parameters

7 Commissioning

7.1

Setting up the welding machine

7.2

Mains connection

7.2.1

Switching the control transformer to 415V mains voltage

7.3

Cooling the welding machine

7.4

Water cooling for welding torches

7.5.

Connecting the WF hose package to the current source

7.5.1 MIG series with integral DRIVE 4/4S, integral DRIVE 4 L, integral DRIVE 4 D

integral

inverter

7.5.2 MIG/TIG series with integral DRIVE 4 T

integral

inverter

7.6.

Connecting or exchanging the hose package at the WF case

7.7

Welding torch connection

7.7.1 MIG welding torch

7.7.2 Connection of MIG Push/Pull torch

7.7.3 Connection of MIG Up/Down (working point) torch

7.7.4 Connection of TIG-combo welding torch (MIG machines)

7.7.5 Connection of TIG welding torch (MIG/TIG machines)

7.8

Inserting the wire electrode

7.8.1 Exchanging the wire feed rollers at the wire feed

7.8.2 Installing the wire reel

7.8.3 Inching wire electrode

7.8.4 Adjusting the contact pressure

7.9

Workpiece cable and electrode holder

integral

inverter

7.9.1 MIG 300

puls

compact

integral

inverter

7.9.2 MIG series with WF case

integral

inverter

7.9.3 MIG/TIG series with WF case

5/14

5/14

5/15

5/16

5/16

5/17

5/18

5/18

5/19

5/20

6/1

6/1

6/1

6/2

6/2

7/1

7/1

7/1

7/1

7/2

7/2

7/3

7/3

7/4

7/5

7/6

7/6

7/6

7/7

7/8

7/9

7/9

7/9

7/10

7/10

7/11

7/11

7/11

7/11

7/11

Table of Contents

Page

8

9

10

11

7.10 Shielding gas supply

7.10.1 Making the gas connections

7.10.2 Gas connection

7.10.3 Gas connection

7.10.4 Gas connection

7.10.5 Shielding gas adjustment (gas test)

7.10.6 Shielding gas adjustment

integral

inverter

MIG 300

puls

compact

integral

inverter

MIG - series

MIG/TIG series

integral

inverter

integral

inverter

MIG series

Adjusting instructions (pending)

Maintenance and care

Operating faults, causes and cures

10.1 Customer checklist

Spare parts list

integral

inverter

11.1 MIG 300 puls

compact

,

integral

inverter

MIG 300 puls

11.1.1 Front view

11.1.2

11.1.3 Inside view, left

11.1.4 Inside view, right

Rear view

11.2 MIG 450 puls ,

integral

inverter

integral

inverter

11.2.1

Front view

integral

inverter

MIG 500 puls , MIG 450 puls ,

integral

inverter

MIG/TIG 450 puls , MIG 500 puls

integral

inverter

integral

inverter

MIG/TIG 500 puls

11.2.2 MIG/TIG 450 puls ,

Front view

integral

inverter

11.2.3 MIG 450 puls ,

Rear view

integral

inverter

integral

inverter

11.2.4 MIG/TIG 450 puls ,

Rear view

integral

inverter

integral

inverter

MIG/TIG 500 puls

MIG 500 puls

integral

inverter

MIG/TIG 500 puls

11.2.5 Inside view, left

11.2.6 Inside view, right

11.2.7 Inside view MIG/TIG unit

11.3 Wire feed case

11.3.1 Front view

11.3.2 Inside view

11.3.3 Explosion drawing wire feed unit DRIVE 4

12.

13.

14.

Incorporated HF ignition unit of the

Accessories

Circuit diagrams

integral

inverter

MIG/TIG series

7/12

7/12

7/12

7/12

7/12

7/12

7/13

7/12

9/1

10/1

10/1

11/1

11/1

11/1

11/2

11/3

11/4

11/5

11/5

11/6

11/7

11/8

11/9

11/10

11/11

11/12

11/12

11/13

11/14

12/1

13/1

14/1

Safety instructions

For Your Safety:

Warning:Safety instructions For Your Safety: Observe accident prevention regulations. Ignoring the following safety procedures can

Observe accident prevention regulations.

Ignoring the following safety procedures can be fatal.

Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves.

Protect eyes and face with protective visor.

Electric shocks can be fatalgloves. ∑ Protect eyes and face with protective visor. ∑ The machine may only be connected

The machine may only be connected to correctly earthed sockets.

Only operate with intact connection lead including protective conductor and safety plug.

An improperly repaired plug or damaged mains cable insulation can cause electric shocks.

The machine may only be opened by qualified and authorised personnel.

Before opening, pull out the mains plug. Switching off is not sufficient. Wait for 2 minutes until capacitors are discharged.

Always put down welding torch, stick electrode holder in an insulated condition.

Even touching low voltages can cause you to jump and lead to accidents, so:torch, stick electrode holder in an insulated condition. ∑ ∑ ∑ ∑ Secure yourself from falls

Secure yourself from falls before working on platforms or scaffolding.

When welding, operate earth tongs, torch and workpiece properly, not in ways for which they are not intended. Do not touch live parts with bare skin.

Only replace electrodes when wearing dry gloves.

Never use torches or earth cables with damaged insulation.

Smoke and gases can lead to breathing difficulties and poisoning.Never use torches or earth cables with damaged insulation. ∑ ∑ ∑ Do not breathe in

Do not breathe in smoke and gases.

Ensure that there is sufficient fresh air.

Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarbon fumes can be converted into poisonous phosgene by ultraviolet radiation.

Workpiece, flying sparks and droplets are hotconverted into poisonous phosgene by ultraviolet radiation. ∑ ∑ ∑ Keep children and animals well away

Keep children and animals well away from the working area. Their behaviour is unpredictable.

Move containers with inflammable or explosive liquids away from the working area. There is a danger of fire and explosion.

Never heat explosive liquids, dusts or gases by welding or cutting. There is also a danger of explosions when apparently harmless substances develop high pressures in enclosed containers by heating.

Take care to avoid fire hazardsdevelop high pressures in enclosed containers by heating. ∑ ∑ ∑ ∑ Any kind of fire

Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying, when parts are glowing or hot slag is present.

A constant check must be kept on whether fire hazards have been created in the working area.

Highly inflammable objects, such as matches and cigarette lighters for example, must not be carried in trouser pockets.

You must ensure that fire extinguishing equipment - appropriate to the welding process - is available close to the welding work area and that easy access is possible.

Safety instructions

Take care to avoid fire hazardsSafety instructions ∑ ∑ ∑ Containers in which fuels or lubricants have been present must be

Containers in which fuels or lubricants have been present must be thoroughly cleaned before welding begins. It is not sufficient simply for the receptacle to be empty.

After a workpiece has been welded, it must only be touched or brought into contact with inflammable material when it has cooled down sufficiently.

Loose welding connections can completely destroy protective conductor systems of interior installations and cause fires. Before beginning welding work, ensure that the earth tongs are properly fixed to the workpiece or welding bench and that there is a direct electrical connection from the workpiece to the power source.

Noise exceeding 70 dBA can cause permanent hearing damageconnection from the workpiece to the power source. ∑ ∑ Wear suitable earmuffs or plugs. Ensure

Wear suitable earmuffs or plugs.

Ensure that other people who spend time in the working area are not inconvenienced by the noise.

Secure gas cylinderin the working area are not inconvenienced by the noise. ∑ ∑ ∑ Place shielding gas

Place shielding gas cylinders in the holders provided for them and secure with safety chains.

Take care when handling cylinders; do not throw or heat, guard against them toppling over.

When moving by crane, take off the gas cylinder from the welding machine.

Caution: Interference by electric and electromagnetic fields can be caused by the welding machine or by the high-voltage pulses of the ignition unit.crane, take off the gas cylinder from the welding machine. ∑ As laid down in Electromagnetic

As laid down in Electromagnetic Compatibility Standard EN 50199, the machines are intended f use in industrial areas; if they are operated e.g. in residential environments problems can occur ensuring electromagnetic compatibility.

The functioning of heart pacemakers can be adversely affected when you are standing near the welding machine.

Malfunctioning of electronic equipment (e.g. EDP, CNC equipment) in the vicinity of the welding location is possible.

Other mains supply leads, trip leads, signal and telecommunications leads above, under and near the welding device may be subject to interference.

Warning:and near the welding device may be subject to interference. Electromagnetic interference must be reduced to

Electromagnetic interference must be reduced to such a level that it no

longer constitutes interference. Possible reduction measures:

Welding equipment should be serviced regularly. (see Sect. Maintenance and care)

Welding leads should be as short as possible and run closely together on or near to the ground.

Selective shielding of other leads and equipment in the environment can reduce radiation.

specialist personnel. The warranty becomes null and void in the event of unauthorisedleads and equipment in the environment can reduce radiation. Caution: Repairs and modifications may only be

Caution:

Repairs and modifications may only be carried out by authorised, trained,

interference.

Our operating instructions will provide you with an introduction into the safe use of the machine. Therefore please read them closely and only start work when you are familiar with them.unauthorised Caution: Repairs and modifications may only be carried out by authorised, trained, interference. Sicherheit/2

1

About this Unit Manufactured in Inverter Technology

1.1 Advantages of inverter technology and the INTEGRAL process:

Congratulations.

The INTEGRAL PROCESS is an absolute world-wide novelty. It makes perfect welding and the simplest operation possible. Highly modern microprocessors automatically calculate and monitor all parameters for an optimum arc. Equipped with this, our newly developed, intelligent inverter MIG/MAG units provide an optimum welding quality, user- friendliness and economy.

Oriented to the future

Reliable

Functional

User-friendly

Versatile

Flexible

Economical

Service-friendly

Quiet

Reliable

DIN ISO 9000

with chip technology, new, improved welding programs can be easily incorporated

with excellent ignition and welding characteristics, even during mains voltage fluctuations

with rugged construction and highly-integrated electronics

by clear, appropriate arrangement of all operating elements

MIG/MAG pulse, MIG/MAG standard (TIG HF and Liftarc ignition) and MMA welding possible

Connections for:

- Manual remote control

integral C10, C20, C30, C40, superPuls SP10 and SP11,

- Robot interfaces RINT 1 and 2,

- Interface for mechanised welding as a standard

by high efficiency and favourable cos .

by modular design and small diversity of parts

with silenced fan control

by temperature monitors in the power circuit

standard connection of the documentation interface PCINT 1 for welding data documentation for DIN EN ISO 9000ff.

1

About this Unit Manufactured in Inverter Technology

1.2 Integral welding process

By the consistent use of the latest microprocessor technology in conjunction with current source dynamics which can only be attained with inverter technology, it was possible to produce an arc of hitherto unknown perfection and stability by the INTEGRAL welding process.

This makes a new generation of welding machines available to the user, which are characterised by

the most simple operation

high user-friendliness

high flexibility by adaptation to every welding task

welding characteristics

which were unattainable until now.

In the INTEGRAL process, the analogue regulators previously common in welding machines have been replaced by a digital system. The heart of the INTEGRAL welding process is a mathematical model of the arc. With this mathematical arc model, the microprocessor calculates the optimum process parameters according to the

type of material,

type of gas and

wire diameter

for all welding methods. The actual arc parameters are compared with the calculations of the model 50,000 times per second and if deviations are found, new nominal values are issued to the inverter power unit. The highly dynamic inverter power unit, which operates with an extremely high clock frequency of up to 150 kHz, compensates these deviations within only a few microseconds and thereby optimises the arc at all times.

1

About this Unit Manufactured in Inverter Technology

The welder is thereby provided with a smooth, quiet and easily handled arc of unsurpassed perfection both for MIG / MAG pulse welding and for MIG / MAG standard welding. Beyond this, all welding machines of the INTEGRAL series are capable of issuing all actual values of the welding process such as

welding voltage,

welding current,

wire speed and

the armature current of the wire feed motor

for documentation purposes at any time to a standard PC. With the aid of the Windows software Q-DOC 9000, these parameters can be viewed graphically, processed, stored or issued to a printer.

The INTEGRAL process therefore represents a complementary, complete system which opens completely new dimensions both for manual and automatic welding.

completely new dimensions both for manual and automatic welding. Basic circuit diagram "Integral process" 1/3

Basic circuit diagram "Integral process"

1

About this Unit Manufactured in Inverter Technology

1.3 General description of the machine

All

The welding machines are mobile and can be transported with cranes.

integral

inverter

welding machines and integral wire feed cases are contained in a rugged sheet steel casing.

The portable integral wire feed cases are all equipped with a Euro central connection. They are available in numerous designs, e.g.:

integral DRIVE 4 standard wire feed case or

integral DRIVE 4 S with a stronger, particularly powerful wire feed.

For further wire feeds, see the system overview

The DRIVE 4 and DRIVE 4S WF cases can be optionally equipped with a star handle or wheel set. For applications which require high flexibility, twin wire feed cases are available. All wire feed units have tacho regulation to ensure a constant wire feed speed (actual angular speed measured by a digital incremental encoder).

3 controllers are available to the user to input and display the desired welding parameters and to control the welding process.

integral MIG, integral MIG PROGRESS 4 or integral MIG PROGRESS

The controllers can also be exchanged at a later time simply and without opening the unit.

The

current becomes excessive by thermal switches in the power unit.

integra

inverter

welding machines are protected against overloading if the service cycle is exceeded or the

The following remote controls are available as accessories:

Manual remote control

integral C10, C20, C30, C40, superPuls SP10 and SP11,

Options:

twin cyclinder holder,

other mains voltages,

flow rate monitors

connections for up/down, push/pull and small spool torches.

Star handle

Wheel set

Documentation interface PCINT 1

Robot interface RINT 1 and RINT 2

1

About this Unit Manufactured in Inverter Technology

1.4 integral controllers

1.4.1 integral MIG, integral MIG PROGRESS 4

The operation concept and the functions of both controllers are largely identical. The welding task, defined by the type of material, type of gas, wire electrode diameter and welding process is selected in the unit from a job overview list and is entered as a job directly into the controller.

20 permanently pre-programmed MIG/MAG jobs (for most welding tasks),

9 user-programmable jobs (customer-specific applications),

1 TIG and 1 MMA job.

Expert mode User-specific modification of the basic welding parameters.

The basic difference between intergal MIG and integral MIG PROGRESS 4 lies in the number of welding programs (working points) per welding operation and a down-slope facility.

integral MIG:

One welding program (working point) with down-slope at the end of the weld seam.

integral MIG PROGRESS 4:

4 welding programs (working points):

a starting program (P1) to heat the plate,

a main current program (P2) and

an end-crater program (P4).

In latched operation, it is also possible to reduce the main current (P3).

1

About this Unit Manufactured in Inverter Technology

1.4.2 integral TIG PROGRESS

The welding task defined by the type of material, type of gas, wire electrode diameter and welding process are entered directly in plain language with keys and LED user support.

2 user-programmable memory spaces (customer-specific applications).

Expert mode User-specific modification of the basic welding parameters.

One welding program (working point) with down-slope at the end of the weld seam.

1.5 Area of application

MIG / MAG pulse welding using argon or argon-enriched shielding gases.

MIG / MAG standard welding with short, compound or spray type arc using argon, gas mixtures and CO2.

TIG welding.

MMA welding.

Materials:

Solid and core wire electrodes.

Low and high-alloyed steels, aluminium and nickel base alloys, copper and its alloys.

Areas of use:

The chemicals industry, machine building, automotive construction, tank and plant equipment building, shipbuilding, metal processing industry.

Standard applications and complex, customer-specific welding tasks.

All integral

inverter

welding machines fulfil the requirements for welding with increased electrical hazard and

can therefore be marked with the

S
S

symbol.

2

Transport and Installation

The units may only be transported and operated in an upright position.2 Transport and Installation ∑ Secure high-pressure shielding gas cylinder with safety chain to prevent it

Secure high-pressure shielding gas cylinder with safety chain to prevent it from toppling over.may only be transported and operated in an upright position. ∑ ∑ Before moving, pull out

Before moving, pull out mains plug and place on the machine.

Do not roll over hoses or cables.

securing chain.place on the machine. ∑ Do not roll over hoses or cables. Place the shielding gas

Place the shielding gas cylinder in the cylinder holder and secure it in place with the

Maximum permissible cylinder size at internal pressure:

200 bar, up to 50 l geometrical volume

300 bar, up to 33 l geometrical volume

When the current source is moved and positioned, it is only secure against falling to an volume ∑ 300 bar, up to 33 l geometrical volume angle of 15° (as specified in

angle of 15° (as specified in EN 60974-1). Special attention should be paid to the fact that,

when the unit is moved, additional danger results from obstacles on the floor as these can

cause additional tilting moments.

Safety rules for crane transport

additional tilting moments. Safety rules for crane transport ∑ Carefully observe the accident prevention regulations

Carefully observe the accident prevention regulations VBG 9, VBG 9a and VGB 15.

accident prevention regulations VBG 9, VBG 9a and VGB 15. Fig. 1: Crane principle mind. 60°

Fig. 1:

Crane principle

mind. 60° Fig. 2: mind. 1m
mind. 60°
Fig. 2:
mind. 1m

Angle of the suspension ropes

Lift with the crane at all 4 ring screws simultaneously (as depicted in Fig. 1).

Ensure an even distribution of the load to all four ropes and maintain an angle of at least 60° of the suspension ropes (see Fig. 2). Use only ring chains or suspension ropes of equal length (at least 1 m).

Load hooks with securing cleats and skackles of

corresponding size to DIN 82 101, Form A. Use minimum rated size 0.4.

Before lifting with a crane, always remove the shielding gas cylinder from the welding

unit.

Never lift other loads together with the welding machine,

e.g. persons, toolboxes, wire spools etc.

Avoid jerks when raising and lowering the welding machine.

2

Transport and Installation

Environmental conditions:

The welding machine can be operated in a location where there is no risk of explosion at

an ambient temperature

a relative air humidity

of -10°C (plasma machines 0°C) to +40°C and

up to 50% at 40°C.

where the surrounding air is free of unusual amounts of dust, acids, corrosive gases or substances etc., insofar as they do not occur during welding. Examples of unusual operating conditions:

Unusual corrosive smoke, vapour, excessive oil vapour, unusual vibrations or jolts, excessive quantities of dust such as grinding dusts etc., severe weather conditions, unusual conditions near the coast or on board ship.

When installing the machine, ensure a free inlet and outlet of air. The machine is tested according to protection class IP23, i.e.:

Protection against penetration of solid foreign bodies > 12mm,

Protection against water spray up to an angle of 60° to the vertical.

Notes on the use of these operating instructions

These operating instructions are arranged in Sections. To help you find your way around more quickly, in the margins you will occasionally see, in addition to sub-headings, icons referring to particularly important passages of text which are graded as follows depending on their importance:

Applies to technical peculiarities which must be observed by the user.which are graded as follows depending on their importance: (Note): Applies to working and operating procedures

(Note):

Applies to working and operating procedures which must be followed precisely to avoid damaging or destroying the machine.peculiarities which must be observed by the user. (Note): (Warning): Applies to working and operating procedures

(Warning):

Applies to working and operating procedures which must be followed precisely to avoid endangering people and includes the „Warning“ symbol. precisely to avoid endangering people and includes the „Warning“ symbol.

(Caution):

Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet points, e.g.:

Insert plug of welding current lead into socket (Sect. 5, G2) and lock.

Meaning of the diagram descriptions:

e.g. (C1) means:

e.g. (Sect. 3, C1) means: In Section 3 Item C / Figure 1

Item C / Figure 1 in the respective section

3

Technical data

3.1

integral

inverter

MIG series

integral

MIG series

integral

MIG 300

puls

integral

MIG 300 puls

integral

MIG 450 puls

integral

MIG 500 puls

inverter

inverter

compact

inverter

inverter

inverter

Setting range

 

5A - 300A

 

5A - 450A

5A - 500A

MIG welding voltage

 

14.2V - 29V

 

14.2V - 36.5V

14.2V - 39V

TIG welding voltage

 

10.2V - 22V

 

10.2V - 28V

10.2V - 30V

MMA welding voltage

 

20.2 - 32V

 

20.2V - 38V

20.2V - 40V

Duty cycle, max welding current at

 

40,0°C

 

35%ED

 

300A

   

450A

 

-

 

60%ED

 

250A

   

350A

 

500A

 

100%ED

 

190A

   

270A

 

400A

Duty cycle, max welding current at

 

20°C

 

100%ED

 

225A

   

310A

 

460A

Load alternation

 

10 min

 

Mains voltage

 

3

x 400V (+20%;-25%) / 3 x 415V (+15%;-25%)

 

Frequency

 

50 / 60Hz

 

Max. connected power

 

15.5kVA

   

26.6kVA

 

29 kVA

Recommended generator rating

 

19.6kVA

   

33.8kVA

 

39.2kVA

Open-circuit voltage

 

At 400V mains voltage

 

106V

   

79V

 

At 415 V mains voltage

 

110V

   

82V

 

Mains fuses, slow-blow

 

3

x 16A

   

3 x 25A

 

3 x 35A

Workpiece lead

 

35mm 2

   

50mm 2

 

95mm 2

Efficiency

 

85%

   

89%

 

91%

Power factor cos phi

 

0,99

 

Wire feed speed

1m/min - 20m/min

 

--

Standard wire feed roller fitting for steel

1.0 +1.2 mm

   

--

Ambient temperature

 

-10C to +40C

 

Unit cooling

 

Fan

 

Torch cooling

 

air

   

water

 

Tank capacity

 

-

 

7l

Euro-central connection

 

Yes

 

Insulation class

 

H

Protection class

 

IP 23

 

Dimensions without gas cylinder L/W/H

 

970mmx410mmx920mm

 

970mmx510mmx920mm

incl. cylinder holder

incl. cylinder holder

Weight without accessories

 

80kg

 

70kg

 

110kg

 

120kg

3

Technical data

3.2

integral

inverter

MIG/TIG series

integral

MIG/TIG series

integral

MIG/TIG 450 puls

integral

MIG/TIG 500 puls

inverter

inverter

inverter

Setting range

 

5A - 450A

 

5A - 500A

MIG welding voltage

 

14.2V - 36.5V

 

14.2V - 39V

TIG welding voltage

 

10.2V - 28V

 

10.2V - 30V

MMA welding voltage

 

20.2V - 38V

 

20.2V - 40V

Duty cycle, max welding current at 40°C

 
 

35%ED

 

450A

 

-

 

60%ED

 

350A

 

500A

 

100%

 

270A

 

400A

Duty cycle, max welding current at 20°C

 
 

100%ED

 

310A

 

460A

Load alternation

 

10min

 

Mains voltage

 

3 x 400V (+20%;-25%) / 3 x 415V (+15%;-25%)

Frequency

 

50

/ 60Hz

Max. connected power

 

26.6kVA

 

29 kVA

Recommended generator rating

 

33.8kVA

 

39.2kVA

Open-circuit voltage

 

At 400V mains voltage

 

79V

At 415 V mains voltage

 

82V

Mains fuses, slow-blow

 

3 x 25A

 

3 x 35A

Workpiece lead

 

50mm 2

 

95mm 2

Efficiency

 

85%

 

91%

Power factor cos phi

 

0,99

Ambient temperature

 

-10-C to +40C

 

Machine cooling

 

Fan

Torch cooling

 

water

 

Tank capacity

 

7l

Euro-central connection

 

Yes

Insulation class

 

H

Protection class

 

IP 23

Dimensions without gas cylinder L/W/H

 

970mmx410mmx920mm (incl. cylinder holder)

Weight without accessories

 

140kg

 

150kg

3.3 WF case integral DRIVE 4/4S, integral DRIVE 4T, integral DRIVE 4D

integral

inverter

MIG series

integral DRIVE 4

integral DRIVE 4S

integral DRIVE 4T

integral DRIVE 4D

Supply voltage

 

42

V AC

Max. welding current at 60%ED

 

500A

Wire feed speed

 

1m/min - 20m/min

 

Standard wire feed roller fitting for steel

 

1.0 +1.2mm

 

Ambient temperature

 

-10-C to +40C

 

Euro-central connection

 

Yes

Drive

 

4 rollers

 

Protection class

 

IP 23

Dimensions (LxWxH)

 

680 x 460 x 265

655 x 460 x 495

Weight without accessories, incl. intermediate hose package 1.5.

 

24kg

48,5kg

4

Description of the System Components

4.1 System overview

TIG torch (HF / Liftarc) TIG unit for TIG HF ignition 4m Wire feed case
TIG torch
(HF / Liftarc)
TIG unit for TIG HF ignition
4m
Wire feed case
Centralised or
Small spool torch D100
decentralised design
(Option: works-adjusted function)
integral DRIVE
D2004
(with WF in "T" version only)
Options:
Twin cylinder
Flow monitor
3m
bracket (Option)
MIG torch
Wire feed
casetwin
Star handle Option)
integral DRIVE
4
D
3m
Control system:
Intermediate
MIG torch
Up / Down
1 rocker / 2 rockers
tube package:
(Option:
works-adjusted function
)
integral MIG PROGRESS (III.),
1,5; 5; 10;
i nte gra l MIG PROGRESS 4
20m
i nte gra l MIG,
Push Pull -
torch
8m
Wire feed unit
1 (Option:
potentiometer / 2 potentiometers
integral
MIG PROGRESS 4
works-adjusted function)
integral DRIVE
P1
P1
JobJob
P2
P3
P4
Start
Start
1
2
3
4
5
4
L
TIG combo
-
+
MODE
6
7
8
9
0
SET
torch (Liftarc)
4m
integral
MIG 300 puls
(air)
inverter
compact
with integrated WF
integral
puls
MIG 300
(air)
inverter
integral
puls
MIG 450
(water)
inverter
integral
puls
MIG 500
(water)
inverter
integral
puls
MIG / TIG 450
(water)
inverter
integral
puls
MIG / TIG 500
(water) puls
inverter
integral
MIG 500 HIGH SPEED
inverter
Remote
Remote
Remote
Remote
(water)
control
control
control
control
integral C10
integral C20
integral C30
integral C40
Connection to
WF Case
Wire feed case
integral DRIVE
Extension lead:
PORTABLE
inverter MIG 300 pulsintegral
4 / 4S,
FRV 10-I; FRV 20-I
integral
puls
MIG
4T
inverter
300 compact
with integrated
WF (air)
Intermediate
tube package:
Extension lead
10m; 20m
FRV 10-I
Wire feed rollers
PC INT 1
RINT 1 / 2
for steel, aluminium, cored wire
Documen-
Robot
tation
interface,
Remote
Remote
interface
internal also
control
control
Extension lead
(Option)
(Option)
Wheel assembly kit
superPuls SP10
superPuls SP11
PCV 5-I, PCV 10-I
(Option)
Intermediate
Accessories
:
PC with
drive 4x4
MIG torch
Q DOC
9000
Printer
Workpiece lead,
electrode holder,
in conjunction with
compact unit or
intermediate tube package
3m
pressure reducer,
<1.5m
gas tube
,(2m)
19.04.1999
coolant

4

Description of the System Components

4.2 The welding current sources

integral

inverter

MIG 300 puls and

integral

inverter

MIG 300

puls

compact

p u l s and integral inverter MIG 300 puls compact (Compact version only) Front view
p u l s and integral inverter MIG 300 puls compact (Compact version only) Front view
(Compact version only)
(Compact version only)

Front view

integral

inverter

MIG 300 puls and

integral

inverter

MIG 300

puls

compact

4

Description of the System Components

A1

Rotary dial to correct the electric arc length

B1

Changeover switch remote control

( integral MIG, integral MIG PROGRESS 4 only)

C1

Rotary dial for wire feed speed 1 – 20 m/min

( integral MIG, integral MIG PROGRESS 4 only)

D1

Lifting lugs

E1

Control panel

( integral MIG PROGRESS)

F1

Main switch:

machine on/off

G1

Air inlet openings

H1

Control panel

( integral MIG, integral MIG PROGRESS 4))

I1

Connection socket for remote control

( integral MIG, integral MIG PROGRESS 4 only)

J1

Euro-central connection (compact version only)

K1

Welding current socket +

Workpiece lead connection for TIG welding method

L1

Welding current socket -

Workpiece lead connection for TIG/MAG welding method

Welding current connection for TIG welding method

4

Description of the System Components

4 Description of the System Components Rear view integral inverter MIG 300 puls compact a n

Rear view

integral

inverter

MIG 300

puls

compact

and

integral

inverter

MIG 300 puls

4

Description of the System Components

 

A2

Securing chains for gas cylinder

 
 

B2

Mains connection cable

 
 

C2

Air outlet openings

D2  Interface for mechanised welding EB3  

 

Interface for mechanised welding EB3

 
 

E2

7-pole connection socket (in parallel with F2) Power supply and control for wire feed unit

 

F2

7-pole connection socket (in parallel with E2) Connection facility for PCINT 1, RINT 1 / 2 or remote control

 

G2

Gas connection G ¼ (

integral

inverter

MIG 300

puls

compact

only)

H2  Earthing screw (PE)

 

Earthing screw (PE)

 

I2

Fuse 4A / 250V slow-blow

 
 

J2

Welding current socket + Welding current connection socket for wire feed case in TIG/MAG welding.

 

K2

Welding current socket -

 

4

Description of the System Components

integral MIG integral MIG PROGRESS 4 - + - + P1 P4 JOB JOB P2
integral MIG
integral MIG PROGRESS 4
-
+
-
+
P1
P4
JOB
JOB
P2
P3
START
END
1 2
3
4
5
1 2
3
4
5
-
- +
MODE
+ MODE
6 7
8
9
0
6 7
8
9
0
SET
SET

A3

B3

C3

MODE 6 7 8 9 0 6 7 8 9 0 SET SET A3 B3 C3
MODE 6 7 8 9 0 6 7 8 9 0 SET SET A3 B3 C3

D3

D3

E3

F3

8 9 0 SET SET A3 B3 C3 D3 D3 E3 F3 Front view integral MIG
Front view integral MIG 450 puls inverter
Front view
integral
MIG 450 puls
inverter

rear view

integral

inverter

MIG 450 puls

4

Description of the System Components

 

A3

Lifting lugs

 

B3

Control panel

( integral MIG, integral MIG PROGRESS 4) or integral MIG PROGRESS)

 

C3

Main switch:

unit on/off

 

D3

Air inlet openings

 

E3

Welding current socket +, workpiece for TIG

 

F3

Welding current socket -

Workpiece lead connection for TIG/MAG welding method

Welding current connection for TIG welding method

A4Automation interface

Automation interface

B4  7-pole connection socket (in parallel with C4) Connection facility for PCINT 1, RINT 1

 

7-pole connection socket (in parallel with C4) Connection facility for PCINT 1, RINT 1 / 2 or remote control

C4  7-pole connection socket (in parallel with B4) Power supply and control for wire feed

 

7-pole connection socket (in parallel with B4) Power supply and control for wire feed unit

 

D4

Welding current socket + Welding current connection socket for wire feed case in TIG/MAG welding.

 

E4

Welding current socket -

F4  Earthing screw (PE)

 

Earthing screw (PE)

 

G4

Rapid-action closure coupling (blue):

Coolant supply

 

H4

Rapid-action closure coupling (red):

Coolant return

 

I4

Mains connection cable

 

J4

Securing chains for gas cylinder

 

K4

Air outlet openings

 

L4

Coolant filling pipe

 

M4

Upper coolant level gauge

 

N4

Lower coolant level gauge

4

Description of the System Components

4.2.3

integral

inverter

MIG/TIG 450 puls and integral

inverter

MIG/TIG 500 puls

DEZENTRALand i n t e g r a l inverter MIG/TIG 500 p u l s

t e g r a l inverter MIG/TIG 500 p u l s DEZENTRAL ZENTRAL integral
t e g r a l inverter MIG/TIG 500 p u l s DEZENTRAL ZENTRAL integral
t e g r a l inverter MIG/TIG 500 p u l s DEZENTRAL ZENTRAL integral

ZENTRAL

integral MIG integral MIG PROGRESS 4 - + - + P1 P4 JOB JOB P2
integral MIG
integral MIG PROGRESS 4
-
+
-
+
P1
P4
JOB
JOB
P2
P3
START
END
1
2
3
4
5
1
2
3
4
5
-
+
-
+
MODE
MODE
6
7
8
9
0
6
7
8
9
0
SET
SET

Front view integral

inverter

MIG/TIG 500 puls

4

Description of the System Components

TIG

A5

Workpiece connection socket for TIG/MAG welding

TIG +

B5

Workpiece connection socket for TIG welding

C5  Rapid-action closure coupling (red):

 

Rapid-action closure coupling (red):

Coolant return from TIG torch

D5  Connection socket for TIG torch control cable

 

Connection socket for TIG torch control cable

E5  Rapid-action closure coupling (blue):

 

Rapid-action closure coupling (blue):

Coolant supply to TIG torch

F5  Euro-central connection for TIG torch

 

Euro-central connection for TIG torch

G5  Connection nipple G¼ TIG shielding gas output to TIG torch

 

Connection nipple G¼ TIG shielding gas output to TIG torch

-

H5

Welding current socket – Welding current socket for TIG torch

 

I5

Key-operated switch to lock the control system

 

J5

Transparent flap (for rarely used welding parameters)

 

K5

Carrying handle

 

L5

Main switch on/off

 

M5

Fixed castors

 

N5

Control panel

( integral MIG, integral MIG PROGRESS 4) or integral MIG PROGRESS)

 

O5

Lifting lugs

 

P5

Air inlet openings

4

Description of the System Components

4 Description of the System Components Rear view i n t e g r a l
4 Description of the System Components Rear view i n t e g r a l
4 Description of the System Components Rear view i n t e g r a l

Rear view integral

inverter

MIG/TIG 450 puls

 

A6

Connection nipple G¼ TIG shielding gas output to wire feed case

(case A for twin case)

  B6 Changeover switch for: HF ignition
 

B6

Changeover switch for:

HF ignition  B6 Changeover switch for:

Liftarc ignitioncase)   B6 Changeover switch for: HF ignition C6 Connection nipple G¼ TIG shielding gas output

C6 Connection nipple G¼ TIG shielding gas output to wire feed case B

C6

Connection nipple G¼ TIG shielding gas output to wire feed case B

(twin case only)

  D6 Connection nipple G¼ TIG shielding gas input to wire feed case
 

D6

Connection nipple G¼ TIG shielding gas input to wire feed case

(case A for twin case)

(case A for twin case)

E6 Connection nipple G¼ TIG shielding gas input

E6

Connection nipple G¼ TIG shielding gas input

  F6 Connection nipple G¼ TIG shielding gas input to wire feed case B
 

F6

Connection nipple G¼ TIG shielding gas input to wire feed case B

(twin case only)

(twin case only)

G6 14-pole interface for mechanised welding

G6

14-pole interface for mechanised welding

4

Description of the System Components

H6  7-pole connection socket (in parallel with I6) Connection facility for PCINT 1, RINT 1

 

7-pole connection socket (in parallel with I6) Connection facility for PCINT 1, RINT 1 / 2 or remote control

I6  7-pole connection socket (in parallel with H6) Power supply and control for wire feed

 

7-pole connection socket (in parallel with H6) Power supply and control for wire feed unit

+

J6

Welding current socket + Welding current connection socket for wire feed case in TIG/MAG welding.

K6 Earthing screw (PE)

K6

Earthing screw (PE)

 

L6

Upper coolant level gauge

 

M6

Rapid-action closure coupling (blue):

Coolant supply

 

N6

Rapid-action closure coupling (red):

Coolant return

 

O6

Lower coolant level gauge

 

P6

Air outlet openings

 

Q6

Chains for cylinder attachment

 

R6

Coolant filling pipe

 

S6

Cylinder holders (optional twin cylinder holder)

4

Description of the System Components

4.3

The wire feed cases

4.3.1

WF case integral DRIVE 4

4.3.1 WF case i n t e g r a l DRIVE 4 G7 H7 I7
4.3.1 WF case i n t e g r a l DRIVE 4 G7 H7 I7
4.3.1 WF case i n t e g r a l DRIVE 4 G7 H7 I7

G7

H7

I7

J7

K7

H7

L7

H7

A7

B7

C7

D7

E7

F7

H7 L7 H7 A7 B7 C7 D7 E7 F7   Fig. 7 Front view   A7
H7 L7 H7 A7 B7 C7 D7 E7 F7   Fig. 7 Front view   A7
H7 L7 H7 A7 B7 C7 D7 E7 F7   Fig. 7 Front view   A7
H7 L7 H7 A7 B7 C7 D7 E7 F7   Fig. 7 Front view   A7
 

Fig. 7

Front view

 

A7

Connection socket (option) Connection facility for push-pull or up-down torch

 

B7

Carrying handle

 

C7

Rotary dial for wire feed speed 1 – 20 m/min

 

D7

Rotary dial for correction of the arc length.

 

E7

Position "left"

Nominal values for control system active

Position "centre": Remote control in WF case, push/pull, or up/down torch active

Position "right":

external remote control active

 

F7

Connection socket for remote control

 

G7

Slide latch for opening the wire feed case

 

H7

Rubber feet

I7 Euro-central connection

I7

Euro-central connection

 

J7

Engaging pin holder

 

K7

Rapid-action closure coupling (red):

Coolant return from the torch

 

L7

Rapid-action closure coupling (blue):

Coolant supply to the torch

4

Description of the System Components

4.3.2 WF case integral DRIVE 4

With the integral DRIVE 4 D WF twin case, it is possible to weld with different wire electrodes, diameters and shielding gases successively without rebuilding. The case is equipped with 2 Euro-central connections. The desired wire feed "A" or "B" is selected with the associated torch trigger, each of which disables the other wire feed. The wire feed drives of the integral DRIVE 4 D WFD twin case are speed regulated and equipped with an incremental encoder (for actual speed measurement) as a standard for constant wire feed speed.

Function sequence/wire feed locking

When the current source has been switched on, wire feed "A" always becomes active and is ready for operation. The wire feeds "A" and "B" are switched on with the associated torch triggers and disable each other alternately. As long as the torch trigger of wire feed "A" is pressed or as long as welding is in progress, wire feed "B" cannot be switched on with the associated torch trigger.By using the operating elements of the activated wire feeds “A” or “B”, according to switch (E7), the correction of the arc length, and the change of the wire feed speed can be carried out.

and the change of the wire feed speed can be carried out. Remote control operation: Connect

Remote control operation:

Connect the remote control only when the machine is switched off. Both changeover switches E8 must be in position "right". The connected remote control always operates on the wire feed "A" or "B" which is functioning.

4

Description of the System Components

A8

B8

C8

D8

E8

F8

G8

H8

I8

J8

of the System Components A8 B 8 C8 D8 E8 F8 G8 H8 I8 J8 Fig.
of the System Components A8 B 8 C8 D8 E8 F8 G8 H8 I8 J8 Fig.

Fig. 8

Front view integral 4x4D

A8

B8

C8

D8

E8

K8

F8

G8

H8

I8

J8

A8

Carrying handle

B8

Rotary dial for wire feed speed 1 – 20 m/min

C8

Indicator lamp, left or right wire feed case active

D8

Rotary dial for correction of the arc length.

E8

Changeover switch:

Position "left"

Nominal values of the control system keyboard active

Position "centre":

Remote control in WF case active External remote control active

Position "right":

For remote control operation, the changeover switches must

both be in position "right"

F8

Euro-central connection

 

G8

Slide latch for opening the wire feed case

 

H8

Rapid-action closure coupling (red) Coolant return from the torch

 

I8

Rapid-action closure coupling (blue) Coolant supply to the torch

 

J8

Rubber feet

K8

Remote control connection socket

 

4

Description of the System Components

4.4 integral MIG PROGRESS Controller

0 1 Integral MIG PROGRESS E2E1 INFO Al 99 Ar 100 Ar 98 2 Ar
0
1
Integral
MIG PROGRESS
E2E1
INFO
Al 99
Ar 100
Ar 98 2
Ar 95 5
Ar 92 8
Ar 90 5 5
Ar 82 18
CO 2 100
2,0
Al Mg
1,6
V/A
M
Al Si
1,2
START
Cr Ni
1,0
SG
0,8
m/min
Cu Sn
mm
flap

4

Description of the System Components

4 Description of the System Components Control panel ( i n t e g r a

Control panel ( integral MIG PROGRESS)4.4.1

Visible operating components

1
1
Al 99 Al Mg Al Si Cr Ni SG Cu Sn
Al 99
Al Mg
Al Si
Cr Ni
SG
Cu Sn

Pushbutton and LED indicators:

Selection and display of the type of material for welding

2
2
Ar 100 Ar 98 2 Ar 95 5 Ar 92 8 Ar 90 5 5
Ar 100
Ar 98 2
Ar 95 5
Ar 92 8
Ar 90 5 5
Ar 82 18
CO 100
2

Pushbutton and LED indicators:

Selection and display of the type of gas for welding

3
3

Pushbutton and LED indicators:

Selection and display of the wire MMAdiameter for welding

4
4
4 Pushbutton with LED indicators:

Pushbutton with LED indicators:

Selection and display of the MIG/MAG welding process

   
    LED lights: MIG/MAG standard welding

LED lights: MIG/MAG standard welding

LED lights: MIG/MAG pulse welding, neither of the two LED indicators light when MMA of

LED lights: MIG/MAG pulse welding, neither of the two LED indicators light when MMA of TIG is selected

4

Description of the System Components

5
5
5 Pushbuttons with LED indicators: Selection and display of the operating mode

Pushbuttons with LED indicators: Selection and display of the operating mode

Non latched welding or

Latched welding

Latched welding

6
6
6 Pushbuttons with LED indicators: Selection and display of the welding process

Pushbuttons with LED indicators: Selection and display of the welding process

TIG welding or

TIG welding or

MMA welding Neither of the two LED indicators light when MIG/MAG standard or pulse arc

MMA welding Neither of the two LED indicators light when MIG/MAG standard or pulse arc is selected.

7
7
 

Alphanumeric LC display: Display of all entries and parameters

 
 

INFO

 
8
8
START

START

Pushbutton Info and Start :