The Book of Welding

For the workshop and building site 2006 and 2007

Lorch Schweisstechnik GmbH D-71547 Auenwald Postfach 1160 T. +49 (0)7191.503.0 F. +49 (0)7191.503.199 info@lorch.biz www.lorch.biz

913.1000.1/2

You are holding the book of welding Presented by your dealer

Electrode welding CL Page 30 Electrode welding TIG welding H Page 10 Page 28 ISI5 CL TIG welding HT HandyTig

Page 17 Page 20

MIG-MAG welding A Page 34 Page 44 M 2000 M 3000 Page 48 MIG brazing A CuSi M 3030

Page 34 Page 55

Plasma cutting Z Page 64 Helmets/accessories Page 68 Data Page 72

Our day-to-day work is all about putting the best possible instrument in your hands. As you see, we share a joint ambition: Top quality workmanship

Which adds up to 8,760 working hours. 365 days a year - times three. This is the period for which we guarantee the functional characteristics of our products. We are confident that nothing can go wrong with a system or a unit bearing the name Lorch. But in the unlikely event that a fault should occur, we undertake to repair it and to shoulder the cost. As you will appreciate, this does not apply to wearing parts. 3 times longer than the statutory requirement. The law currently requires a fixed warranty on material and production defects in commercially used products of 1 year. Given our outlook on quality, for us this stipulation goes without saying. Subject to correct treatment in line with the operating instructions provided, we will grant you not just 1 years warranty from the date of purchase, but another 2 years on top. But please do tell us where your equipment is being used and who you are. Please return the warranty card ... ... to Lorch, Postfach 1160, D-71547 Auenwald. Otherwise we will NOT be able to fulfil our three-year warranty pledge. The warranty card is enclosed with your unit. You can also register online on www.garantie.lorch.biz. As soon as you have registered, you will receive your binding warranty certificate guaranteeing three years of cover from the date of purchase.
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Full 3-year warranty

Process kn
Electrode welding
Stick electrode Coating Core wire Gas/Slag Arc Melt zone Base material

MIG-MAG welding
Shielding gas nozzle Contact tip Electrode Shielding gas Arc Melt zone Base material

MIG brazing
Shielding gas nozzle Contact tip Soldering electrode Shielding gas Arc Soldering material Base material

Basic knowledge: Electrode welding The electric arc burns between the material and melting electrode. The electrode simultaneously supplies the filler metal. The stick electrode is clamped in an electrode holder and positioned by the welder. Stick electrodes are generally coated. The coating also melts and protects the molten pool and arc against outside air by releasing gases and slag. The slag is removed after the molten pool cools. Devices marked with an (S) can also be used under higher electrical risks. Inverter welders have very good welding properties and are thus also suitable for special electrodes. Nearly all weldable materials can be welded with stick electrodes, e.g. structural steel, boiler steel, steel tubes, cast steel, stainless steel, hard facing steels, etc. Electrode welding is simple and safe. The compact devices are easy to handle and transport. Since no gas is needed, welding can be performed outdoors, even in wind. Electrode weld machines are used in all lines of business, from industry through to craftsmen.

Basic knowledge: MIG-MAG welding With the MIG-MAG method (MIG = Metal Inert Gas/MAG = Metal Active Gas) the electric arc burns between the melting, automatically supplied welding rod (= electrode) and the material. A separately supplied gas protects the arc and welding zone against outside air. The shielding gas and welding rod must be matched to the base material. Weldable materials include: Aluminium, aluminium alloys Method: MIG Wire electrode: matched to the material to be welded Welding shielding gas: Ar, He or mixtures General structural, boiler, tubular steel Method: MAG Wire electrode: SG 1-3 Shielding gas: mixed gas (Ar/CO2) or CO2 Stainless steel, high alloy steel Method: MAG Wire electrode: matched to the material to be welded Shielding gas: Mixed gases (e.g. Ar/CO2 or Ar/CO2/O2) MIG/MAG welding is the most popular welding method nowadays on account of its enormous advantages. The high welding speed, minimum reworking and low distortion ensure high efficiency. The great weld seam strength, excellent thin-sheet properties and simple and safe handling with steel, aluminium and stainless steel make the method universally acceptable.

Basic knowledge: MIG brazing Called MSG (Metal Shielding Gas) brazing according to international standards - is a hard-soldering procedure. The electrical arc burns between the melting, continuously applied brazing wire electrode and the workpiece. The added shielding gas protects the arc and the liquid brazing metal against the influences of the ambient air. The application is as simple as MIG-MAG welding. MIG brazing offers clear advantages for the joining of galvanised sheets compared to MIGMAG welding. Only a fractional zinc melting loss occurs in the immediate brazing zone (zinc melts at 419C, evaporates at 906C) due to the low melting temperatures of the brazing wire (approximately 1000C). The soldering seam features a high corrosion resistance and enables easier surface treatment. The soldering wires consist of copper based alloy with a component of, for example, silicon or aluminium. There is minimal distortion, even on very thin sheets, due to the low heat input. Coated (galvanised, phosphated, aluminised) and uncoated steel sheets, stainless steel and steel/stainless steel compounds (black/white compounds) may be soldered. Soldering seams provide excellent assembly strength. Shielding gas: pure argon or argon with minor additives. Galvanised thin sheet is used in the automotive engineering and building industries, in air conditioning technology, household appliances and in the furniture industry. MIG brazing is ideal for these applications.

nowledge
TIG welding
Gas nozzle Tungsten electrode Shielding gas Electrode Cutting gas Cooling gas Plasma nozzle Plasma arc Base material

Plasma

Einstein

Arc Melt zone Base material

Basic knowledge: TIG welding With the TIG method (TIG = Tungsten Inert Gas) the electric arc burns between the nonmelting tungsten electrode and the workpiece. The arc is very intense and can be very easily controlled. A separately supplied argon shielding gas protects the arc and the welding zone from the atmosphere. Filler metals can be fed by hand or with a special cold wire feed if necessary. Steel, stainless steel, copper, titanium, etc. are welded with direct current. The electrode is connected to the negative pole and ground to a point. Aluminium, magnesium and their alloys should only be welded with alternating current to break open their oxide skin. The electrode is blunt. During welding it can assume a round or crowned shape. With modern inverter power sources, a pointed tungsten electrode can also be used. The advantages of TIG welding: its easy handling and good control over the arc enable very comfortable and clean working. The low oxidisation of the workpiece, small welding zone, omission of fluxing agents and non-spattering arc ensure clean, precise seams with no slag inclusions and no reworking.

Basic knowledge: Plasma cutting When plasma cutting, the electrical arc burns between the non-melting electrode and workpiece. The arc is additionally constricted by a nozzle and applied compressed air, which increases the intensity and stability considerably. Due to this constriction a highly heated gas with high energy content originates in the torch, whose electrical energy is converted into heat. This ionised gas which transfuses the arc onto the workpiece is called plasma. Cuttable materials: By using the plasma-cutting procedure materials such as steel, stainless steel, aluminium, copper, cast, brass, etc. can be cut. The special advantages: Due to the energy density of the plasma arc a high cutting speed is obtained. The cuts are steep, flash- and distortion free and of high economic efficiency. Trouble-free handling and use of simple compressed air as a cutting gas offer unlimited possibilities. Used in the steel industry, installation, container construction and many other areas.

Basic knowledge: E = mc2 ..................................................................... ..................................................................... ..................................................................... ..................................................................... ..................................................................... ..................................................................... ..................................................................... ..................................................................... ..................................................................... .....................................................................

We present: the better inverter.

Drop it? Yes you can. Standards specify that an inverter welding device must be capable of withstanding a free drop of 25 cm. But lets be honest: If a unit falls off a table or out of your hand it will be travelling a good 80 cm before it hits the ground. An H from Lorch is capable of surviving this degree of drop and will still go on working as reliably as ever. We dont know of any other product which can make a similar claim. Statistics show that a unit is bound to be dropped 4 times over its useful life. So your choice of product is already looking a little clearer. Otherwise whats to stop that clumsy apprentice sneaking a damaged unit back on the shelf and you shouldering the blame? Inside coating. This special coating of the electronic circuitry helps protect the inner workings of the inverter against failure due to high or low temperatures, dust, chips and moisture. Consistent HighTec An inverters job is to chop the current it takes from the mains. 100,000 times per second. Power off, power on. And if a part gets out of step by just 100,000th of a second (which is one switching cycle), you are on course for trouble. Digital current controller It takes a perfect microprocessor to regulate the arc correctly. All the better - and all the finer and more controlled the droplet transfer and the spatter formation. Its adaptive behaviour compensates for handling errors and helps stabilise the welding result. Even with difficult electrodes and in awkward confined spaces. It is a Bestseller or a Flop.

Do please measure the duty cycle at 40C The dutycycle (DC) is the measurement variable which determines the loading capacity of a welding unit. In reality, many suppliers are willing to deceive their customers with exaggerated data - or theysimply quote the value at just 20C. Energy-saving inverter technology Minimal power loss - high efficiency. Standby function for minimal energy consumption during breaks. Overvoltage and undervoltage protection Safeguards the unit against damage or defects caused by mains fluctuations within a broad tolerance range. Featuring generous extension cables for convenient use on site. Thermocontrol sensors Reduce the ingress of dirt bycontrolling the fan only as and when required.
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The H
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H150

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Electrode TIG

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Ideal for electrodes up to 3.25 mm. 140 A and an outstanding duty cycle.
Super lightweight. High duty cycle of 30% at 140 A. Simple to operate. Automatic adaptive hot start for perfect ignition. Anti-Stick system prevents electrode sticking. Arc force regulation provides support for difficult electrodes. Durable assembly design, insensitive to knocks, safety due to protection class of IP 23. High mains voltage tolerance, troublefree with long extension leads and good generators. Bears the S label denoting suitability for use in atmospheres subject to higher electrical risk. The standby system reduces fan noise, soiling and energy consumption. H 140, with mains cable, shock-proof plug, transportation belt Order no. 105.0140.0 (PG 12)

New: H140
Electrode welding 1.5-3,25 mm Steel/stainless steel up to 8 mm 5-140 A 30 % 110 A 230 V 4.5 kg

Method Electrode diameter Material electrode Recommended material thickness Welding range Duty cycle at max. current (40) Current at 60% duty cycle (40) Mains voltage Weight

Electrode

H 140 assembly pack All neatly tucked inside. With everything you need for electrode welding. H 140, with mains cable, shock-proof plug, transportation belt, 3 m electrode - and ground cable 16 mm2, slag hammer, wire brush, protection shield EN 166, welding glasses DIN 464647. Complete in a sturdy case with handy compartments. Order no. 105.0141.1 (PG 12) Model 2004 unit: 5.2 kg

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Ideal for electrodes up to 4 mm. Higher powered with 150 A. Good for TIG welding.

New: H1 50
Electrode welding 1.5-4.0 mm Steel, stainless steel up to 10 mm 5 150 A 40 % 135 A 230 V 5.2 kg TIG welding 1.0-2.4 mm Steel, stainless steel, copper 1-4 mm / copper 1-3 mm 5 150 A 40 % 135 A

High performance reserves. Duty cycle of 40% at 150 A. Simple to operate. Automatic adaptive hot start for perfect ignition. Anti-Stick system prevents electrode sticking. Arc force regulation provides support for difficult electrodes. Switchover to TIG welding with ContacTIG ignition for good TIG welding. Durable assembly design, insensitive to knocks, safety due to protection class of IP 23. High mains voltage tolerance, troublefree with long extension leads and good generators. Bears the S label denoting suitability for use in confined spaces in atmospheres subject to higher electrical risk. The standby system reduces fan noise, soiling and energy consumption. H 150, with mains cable, shock-proof plug, transportation belt, order no. 105.0150.0 (PG 12) Method Electrode diameter Weldable material Recommended material thickness Welding range Duty cycle at max. current (40) Current at 60 % DC (40) Mains voltage Weight

Electrode
TIG

H 150 assembly pack Everything you need for electrode welding on the move. An H 150, with mains cable, shock-proof plug, transportation belt, 3 m electrode - and ground cable 25 mm2, slag hammer, wire brush, protection shield EN 166, welding glasses DIN 4646-47. Complete in a sturdy case with handy compartments. Order no. 105.0151.1 (PG 12)

H 150 TIG assembly pack With everything you need for TIG and electrode welding. An H 150, with mains cable, shock-proof plug, transportation belt, 3 m electrode - and ground cable 25 mm2, slag hammer, wire brush, protection shield EN 166, welding glasses DIN 4646-47. Additionally with TIG set comprising: TIG valve torch WLV 17, 4 m; tungsten electrode, pressure reducer with volume and content manometer. All in a sturdy case with handy compartments. Order no. 105.0152.2 (PG 12)

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Professional electrode and TIG welding. High performance reserves with 150 A electrode and 180 A TIG current. High duty cycle of 40% at 150 A (electrode) and 30 % at 180 A (TIG). Automatic parameter system for simple operation: The microprocessor controls the ambient settings on the basis of the welding current and process status. Operator prompting using illuminated symbols. During electrode welding, automatic adaptive hot start for perfect ignition. Anti-Stick system prevents electrode sticking. Arc force regulation provides support for difficult electrodes. Switchover to TIG welding with ContacTIG ignition. Convenient TIG logic operation: The welding current and shielding gas are switched on and off using keys on the torch. No more breakaway of the arc at the end of welding. Automatic gas pre/post flow protects tungsten needle and welding seam from oxidation. 2 and 4 stroke logic for quick tacking and convenient seam welding. Automatic down-slope prevents quality impairing end craters at the end of the seam. Fast down-slope using 2nd torch key prevents fall-through of the seam in case of workpiece overheating. Durable assembly design, insensitive to knocks, safety due to protection class of IP 23. High mains voltage tolerance, troublefree with long extension leads and good generators. Bears the S label denoting suitability for use in confined spaces in atmospheres subject to higher electrical risk. The standby system reduces fan noise, soiling and energy consumption. Remote control facility. H 180c, with mains cable, shock-proof plug, transportation belt, order no. 105.0180.0 (PG 12) Method Electrode diameter Weldable material Recommended material thickness Welding range Duty cycle at max. current (40) Current at 60 % DC (40) Mains voltage Weight Electrode welding 1.5-4.0 mm Steel, stainless steel up to 10 mm 5 150 A 40 % / 150 A 135 A 230 V 5.7 kg TIG welding 1.0-2.4 mm Steel, stainless steel/copper 1-6 mm / copper 1-3 mm 5 180 A 30 % / 180 A 150 A

Enough power for electrodes up to 4 mm. Better TIG welding: 30 A more current plus gas management.

New: H180c

Electrode
TIG

H 180c assembly pack With everything you need for electrode welding on the move. An H 180c, with mains cable, shock-proof plug, transportation belt, 3 m electrode - and ground cable 25 mm2, slag hammer, wire brush, protection shield EN 166, welding glasses DIN 4646-47. Complete in a sturdy case with handy compartments. Order no. 105.0181.1 (PG 12)

H 180c TIG assembly pack With everything you need for TIG and electrode welding. An H 180c, with mains cable, shock-proof plug, transportation belt, 3 m electrode - and ground cable 25 mm2, slag hammer, wire brush, protection shield EN 166, welding glasses DIN 4646-47. plus TIG set, comprising: TIG torch WLT 17K, 4 m; tungsten electrode, pressure reducer with volume and content manometer, plug-in gas hose. Complete in a sturdy case with handy compartments. Order no. 105.0182.2 (PG 12)

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Everything the H180c is capable of, plus no-contact HF and contacTIG ignition. Optimum TIG ignition. The tungsten needle makes no contact with the workpiece. Simply pressing a button ionises the arc channel and initiates the arc. Seams free of tungsten inclusions. Long service life of tungsten needles. Performance pure - 150 A electrode - and 180 A TIG current. Super duty cycle of 40% at 150 A (electrode) and 30 % at 180 A (TIG). Automatic parameter system for simple operation: The microprocessor controls the settings on the basis of the welding current and process status. Operator prompting using illuminated symbols. Convenient TIG sequence: Automatic gas pre/post flow protects the tungsten needle and welding seam from oxidation. 2 and 4 stroke logic for quick tacking and convenient seam welding. Automatic down-slope prevents quality impairing end craters at the end of the seam. Fast down-slope using 2nd torch key prevents fall-through of the seam in case of workpiece overheating. Automatic adaptive hot start for perfect ignition. Durable assembly design, insensitive to knocks, safety due to protection class of IP 23. High mains voltage tolerance, troublefree with long extension leads and good generators. Bears the S label denoting suitability for use in confined spaces in atmospheres subject to higher electrical risk. The standby system reduces fan noise, soiling and energy consumption. Remote control facility. H 180t, with mains cable, shock-proof plug, transportation belt, order no. 105.0185.0 (PG 12)

HighEnd. Enough power for electrodes up to 4 mm. Even better TIG welding due to no-contact HF ignition.

New: H180t

Method Electrode diameter Weldable material Recommended material thickness Welding range Duty cycle at max. current (40) Current at 60 % DC (40) Mains voltage Weight

Electrode welding 1.5-4.0 mm Steel, stainless steel up to 10 mm 5 150 A 40 % / 150 A 135 A 230 V 6.5 kg

TIG welding with HF ignition 1.0-2.4 mm Steel, stainless steel/copper 1-6 mm / copper 1-3 mm 5 180 A 30 % / 180 A 150 A

Electrode TIG
H 180t TIG assembly pack With everything you need for TIG and electrode welding stowed away neatly. The H 180t, mains cable with fitted shock-proof plug, operating manual. Additionally with 3 m electrode and ground cable 25 mm2, slag hammer, wire brush, protection shield EN 166, welding glasses DIN 4646-47, plus TIG set, comprising: TIG torch WLT 17K, 4 m; tungsten electrode, pressure reducer with volume and content manometer, plug-in gas hose. Complete in a sturdy case with handy compartments. Order no. 105.0187.2 (PG 12)

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Accessories
Accessories in detail Assembly wire feeder for all H models, empty Sturdy assembly wire feeder to hold the unit and one set of welding equipment. Order no. 610.0806.0, (PG 12) Autoprotect X 10+11, protection level DIN 10. Converts to DIN 11. MIG-MAG /Electrode welding. Order no. 550.5311.0 (PG12) Autoprotect Flex 9-13 Protection level DIN 9 to 13. Electrode/MIG-MAG/ TIG. Dark/light switching. Sensor bar. Order no. 550.5312.0 (PG12) Autoprotect Multiflex 5-13 Protection level DIN 5 to 13. Electrode/MIG-MAG/TIG. Daylight filter, sensitivity regulator. Goes on where normal helmets give up the ghost. Order no. 550.5313.0 (PG12) TIG wearing parts

Material

Steel and st. steel

Mat. thick- Dia. mm ness, mm tungsten electrode 1.0 1.0 1.5 1.0-1.6 2.0 1.6 3.0 1.6-2.4 4.0 2.4 1.0 1.6 2.4

Welding current, amperes 10-60 40-80 70-120 90-150 140-180 60-80 100-150 150-180

Size ceramic gas nozzle 4 5 5 6 7 4 5 6

Copper 1.0 and copper 1.5 alloys 3.0

Ceramic gas nozzles for TIG torch WLV/WLT 17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 4 5 6 7 5 pcs. 5 pcs. 5 pcs. 5 pcs. PG2 PG2 PG2 PG2 535.8003.4 535.8003.5 535.8003.6 535.8003.7

What you need for TIG welding H 150 TIG lift arc set WLV 17, TIG valve torch WLV17, 4 m Tungsten electrode, pressure reducer Order no. 104.9002.0 (PG12) H 180c and H 180t TIG equipment WLT 17 TIG torch WLT17 K, 4 m Tungsten electrode, pressure reducer, gas hose, ground cable 25 mm2, 4 m. Order no. 105.9001.0 (PG12)

Collets for TIG torch WLV/WLT 17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 1.0 mm 1.6 mm 2.4 mm 5 pcs. PG2 5 pcs. PG2 5 pcs. PG2 535.8000.1 535.8000.2 535.8000.3

TIG supplement H 180c and 180t as above, but without ground cable Order no. 105.9002.0 (PG12)

Collet body for TIG torch WLV/WLT17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 1.0 mm 1.6 mm 2.4 mm 2 pcs. PG2 2 pcs. PG2 2 pcs. PG2 535.8001.1 535.8001.2 535.8001.3

Foot remote control FR 35 with 5 m lead, switches welding current on and off, controls welding current intensity and down-slope. Order no. 570.1135.0 (PG14)

Tungsten electrode gold New-style, lathanised, with excellent ignition properties. Environmentally friendly. 100% radiation free, 175 mm. Order no. Pack Size 1.0 mm 1.6 mm 2.4 mm 10 pcs. PG2 10 pcs. PG2 5 pcs. PG2 535.8006.1 535.8006.2 535.8006.3

Equipment kits in case for TIG Kit 1 for 1.6 mm - WLT 17/26, 3 collets and collet bodies, 5 ceramic gas nozzles size 5;1 W electrode Order no. 551.3051.0 (PG2) Kit 2 for 2.4 mm - WLT 17/26, 3 collets and collet bodies, 5 ceramic gas nozzles size 6;1 W electrode Order no. 551.3052.0 (PG2)

Clamping cap WLV/WLT 17/26 short Replaces the standard torch cap in restricted spaces at the welding position. Order no. 535.8004.1 (PG 2)

Clamping cap WLV/WLT 17/26 long (standard) Replacement torch cap. Order no. 535.8004.2 (PG 2)

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TIG professional
TIG
Electrode

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The new HT 180 AC/DC.

TIG
Electrode

TIG Inverter HT 180 AC/DC. With transportation belt. Order no. 250.0181.1 (PG12) Available from September 2006 AC/DC: TIG for steel, stainless steel, aluminium and electrode welding. Despite the unmistakably handy design, the compact dimensions do nothing to compromise operating simplicity. Just ignite immediate response using minimal current, without touching the workpiece. Can be switched over for ContacTIG ignition. For an intensive, focused, quiet arc, minimal heat input, narrow seam. 2-stroke/4-stroke/spot function. Pulsing operation FastPulse, even. Down-slope function using the 2nd torch button helps prevent fall-through. The welding current is now conveniently controlled directly at the torch. Simply connect the UP/DOWN torch. The variable alternating current frequency and balance take care of optimum aluminium results something only big units have been able to offer in the past. Finally just a few words about adjustment. 3 inputs are all it takes and the automatic parameterization system sets the optimum values for you. Fine tuning any time. From a perfect start to a perfect finish - a flawless seam without end craters.

Method TIG and electrode welding TIG 1.0 3.2 mm Electrode diameter Weldable material Steel, stainless steel/copper/aluminium Recommended material thickness 1 - 8 mm/ 1 - 3 mm/1 - 8 mm Electrode diameter Electrode 1.5 4.0 mm Welding range 3 - 180 A, DC + AC Adjustment Infinitely variable Duty cycle at max. current (40C) 35 % Welding current at 60% DC (40C) 140A Protection class IP23 Mains voltage 230 V Weight 13 kg Scope of delivery: HT 180 AC/DC with mains cable, shock-proof plug, transportation belt.

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The new HT. More advantages.

Crash proof The unit is sitting on the workbench, someone knocks it down. Broken. A working day written off. Units which have adequate protection are not immediately recognizable. The standard stipulates 20 cm. Ever seen a 20 cm high table? We protect the HT at 9 crash points. Which is enough. After all, noone wants to tote a strong box.

Design for practical purposes only. Appearing with a Lorch T under your arm says something about your professional attitude. Compact dimensions, recessed control panel. Logical functions and clearly arranged displays. Nothing to detract from the effective, ergonomic styling.

Just one of many useful details. A dedicated space for the cable, integrated in the handle and closed using Velcro tape. An end to cable spaghetti. And that irritating cable waiting to trip you up just in front of your foot has now gone. A detail maybe. But these are just the points which add up to turn a good unit into a great one.

Dust is death to welding equipment. To some maybe but not ours. We consider this classic trick to shorten the service life of a welding unit to be somewhat below the belt. Dust spells the end for the power electronics. Inside coating, an extra cooling channel for the assemblies and the visible top filter are three answers which make for improved durability.

The trolley. It places the welding unit at a safe and comfortable working height, while those generous and highly stable wheels make for optimized transport. Order no. 570.3035.0 (PG 12) The maxi trolley for additional 50l gas cylinders. Order no. 570.3036.0 (PG 12)

TIG equipment kit WLT 26 DD Complete equipment for TIG welding, comprising TIG torch WLT 26 DD, with double pushbutton. Ground cable 25 mm2, 4m; Pressure reducer with volume and content manometer, gas hose 1.8 m. SET WLT 26DD, 4 m long Order no. 569.2610.4, (PG 12) SET WLT 26DD, 8 m long Order no. 569.2610.8, (PG 12) Complete equipment kit for TIG welding with remote control function at the torch. Comprising TIG torch WLT 26 UD, with double push button und up-down function for remote control of the welding current at the torch. Ground cable 25 mm 2.4m; Pressure reducer with volume and content manometer, gas hose 1.8 m. SET WLT 26 UD, 4 m long Order no. 569.2620.4, (PG 12) SET WLT 26 UD, 8 m long Order no. 569.2620.8, (PG 12)

Hand remote control HR 30 For remote adjustment of the welding current. Complete with 5 m lead. Order no. 570.1031.0 (PG14)

Extension cable set For extending the hand remote control lead. KSF 75, 7.5 m long. Order no. 570.9033.0 (PG14) KSF150, 15 m long. Order no. 570.9036.0 (PG14) Foot remote control FR 35 with 5 m lead, switches welding current on and off, controls welding current intensity and downslope by means of a foot pedal. Order no. 570.1135.0(PG14)

Assembly case HT Sturdy transport case. Protects the unit and equipment. Order no. 610.0808.0 (PG12)

More accesoires on page 23

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No one packs so much power smaller. The HANDY-TIG.

TIG

20

HANDY-TIG 210 DC

HANDY-TIG 210 AC/DC

The truth weighs just 8000 g, is 35 cm long, 13.8 cm wide and 32 cm high. That's all you need to know. Don't be fooled by anyone. You are looking at the smallest "fully professional TIG machine in the world" with some remarkable performance figures. Of course, we could have built it a bit heavier, bigger, with three knobs more and a handle to throw it away with. We would then have been deliberately fooling you, and you would have had to cart it around with you for the rest of your life, assuming it lasted that long. Its operation would also have been a little more difficult thanks to the (extra) knobs and you would have lost not only money but something much more important too: pleasure in your work. So HANDY-TIGs have all the essential qualities of the best TIG welders. Non-contact HF ignition, comfortable TIG sequential logic, 180 A welding output and a duty cycle which allows even the longest of seams. Thanks to our secret SinePowerManagement, you won't lose this inverter output on a 230 V power supply because the mains fuse has blown. The arc is perfect. With steel, stainless steel, copper, aluminium and all conceivable alloys. Whether on a cable drum or generator. Naturally, our two HANDY-TIGs also permit welding with stick electrodes. Four basic settings, that's all you need, and this new friend will open up the world of TIG welding. Learn how to use it in only five minutes by simply turning the page. A glance at the accessories will only serve to whet your appetite.

Technical data Method Electrode diameter TIG Weldable material Recommended material thickness Electrode diameter Welding range Setting Duty cycle at max. current (25/40) Welding current at 60 % DC (25/40) Protection class Mains voltage Weight Protection class Order number (PG12)

HANDY-TIG 210 DC TIG welding Electrode welding 1.0-2.4 mm Steel, stainless steel / copper 1-6 mm / 1-3 mm 1.5-4.0 mm 3-180 A, DC inf. variable 30 % /15 % 135 A /100 A IP23 230 V 8.3 kg IP23 254.0210.0

HANDY-TIG 210 AC/DC TIG welding Electrode welding 1.0-3.2 mm Steel, st. steel / copper /alum 1-6 mm / 1-3 mm / 1-5 mm 1.5-4.0 mm 3-180 A, DC + AC inf. variable 40 % /25 % 135 A /100 A IP23 230 V 11.1kg IP23 254.1210.0

SCOPE OF DELIVERY: System complete with torch WLT 17 DD, 4 m; ground cable 25 mm2, 4 m; pressure reducer with volume and contents manometer, 4 m mains cable with shock-proof plug, fitted gas hose, operating manual

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The operation panel, 1:1

This is where the professional user will find all the necessary functions to optimise the work process. First time users will quickly get the hang of it too. Just 4 settings. And perfect TIG welding will soon become routine.

1. Welding current: Infinitely variable from 3 to 180 amperes.

2. Simple program selection with the Lorch inching logic system and LED display

3. Ignition current: infinitely variable from 7 to 180 amperes.

4. End current down-slope: Program controlled with correction controller.

Programm-Anzeige. Und los gehts.

Program display. And off you go. Carefully engineered functions for optimum convenience. Direct current welding with 2stroke and 4-stroke control. Alternating current welding (HANDY-TIG 210 AC/DC) with 2-stroke and 4-stroke control. In DC operation, lift-arc contact ignition and HF ignition. In AC operation, (210 AC/DC) HF igniAutomatic preflow and postflow. Down-slope using second torch button as a standard feation. ture (prevents fall-through of the molten pool.) Programmed end current down-slope with correction controller for end crater filling. Optimised AC balance with perfect cleaning effect during aluminium welding. Automatic switchover to stick electrode welding when the TIG torch is unplugged. Program storage when changing between TIG and stick electrode welding. Polarity changeover by pressing a button for stick electrodes (210 AC/DC). Remote controllable. SinePowerManagement for maximum output at 230-V mains.

Foot remote control FR 35 with 5 m lead, switches welding current on and off, controls welding current intensity and down-slope. Order no. 570.1135.0(PG14)

Extension cable set complete with cable plug and socket. For extending the hand remote control lead. KSF 75, 7.5 m long, Order no. 570.9033.0 (PG14) KSF 150, 15 m long. Order no. 570.9036.0 (PG14)

Hand remote control HR 30 for remote adjustment of the welding current, complete with 5 m lead. Order no. 570.1031.0 (PG14)

Assembly case HANDY-TIG. Study transport case. Protects the unit and equipment, even space for the Autoprotect helmet. Order no. 602.1227.0 (PG12)

22

Accessories for die HANDY-TIG

Autoprotect helmets. Electronic protective helmets for welders with high-speed darkening. Clear view for positioning the torch and welding wire. Darkens immediately on ignition. For details see page 68.

Autoprotect Flex 9-13, Protection level DIN 9 to 13. Electrode/MIG-MAG/TIG. Dark/light adjustment. Sensor bar. Order no. 550.5312.0, (PG12) Autoprotect Multiflex 5-13 Protection level DIN 5 to 13. Electrode/MIG-MAG/TIG. Daylight filter, sensitivity regulator. Goes on where normal helmets give up the ghost. Order no. 550.5313.0, (PG12)

TIG welding rods are what make the actual joint. Their quality is fundamental to your welding results. Ensure that your welding rods match the material. All rods are 1000 mm long and packaged securely in a tube.

Aluminium AlMg 5 Filler metal for aluminium magnesium alloys. The welding seam area must be metallically bright. Suitable for base materials AlMg 3, AlMg 5, AlZnMg 1, cast alloys with Mg as the main alloy component. 100 rods, AlMg 5; 2.0 mm, Order no. 590.5020.4 (PG 12)

Aluminium Al 99.5 Filler metal for pure aluminium. The welding seam area must be metallically bright. Suitable for base materials Al 99.5, Al 99. 50 rods, 2.0 mm, order no. 590.5120.4 (PG 12) Top-quality TIG glove Supple leather for an optimum feel. Lightweight. Once you have worn them, you wont want to take them off. Size M Order no. 535.8220.0 (PG 12) Size L Order no. 535.8220.1 (PG 12)

Aluminium AlSi 5 Filler metal for aluminium silicon alloys and for joining aluminium alloys of different types. The welding seam area must be metallically bright. Suitable for base materials AlMgSi 0.5, conditionally for AlMgSi 0.8 and AlMgSi 1 and for aluminium cast alloys up to 7 % Si. 100 rods, 2.0 mm, order no. 590.5220.4 (PG 12)

Electrode welding cable with electrode holder 25 mm2, 4 m long, with electrode holder and 13 mm connecting plug. Is required to weld electrodes. Order no. 551.0220.0 (PG 14)

Stainless steel 1.4576 Filler metal for welding unstabilised and stabilised corrosion-proof Cr Ni-Mo steels for operating temperatures up to appr. 400C. Suitable for base materials 1.4401, 1.4404, 1.4435, 1.4436, 1.4437, 1.4571, 1.4573, 1.4480, 1.4581, 1.4583 50 rods , 1.6 mm, order no. 590.5416.3 (PG 12) 50 rods , 2.0 mm, order no. 590.5420.3 (PG 12)

Ground cables with ground clamp and plug Steady, reliable current transmission is imperative to a neat, tidy job. Defective or worn ground cables should be replaced in good time. The original HANDY-TIG cable is available as a spare. 25 mm2, 4 m long, plug 13 mm, order no. 551.0120.0 (PG14)

Stainless steel 1.4370 Filler metal for joints between non-alloyed and lowalloyed steels for operating temperatures up to appr. 300C, cold tough to appr. 120C. Suitable for joints between e.g. St 37-3 with 1.4301. 50 rods , 1.6 mm, order no. 590.5816.3 (PG 12) 50 rods, 2.0 mm, Order no. 590.5820.3 (PG 12)

23

Torch and wearing parts for HANDY-TIG

The original Lorch torch and original Lorch spares are essential components of a HANDY-TIG. There are people who think it is a good idea to produce copies of them. At first glance, you may well save a good 20 - 40% by buying these counterfeit copies. But you can rest assured they are made of cheaper basic materials. Otherwise there would be no profit margin for the plagiarists. After all, our spare parts are just as valuable and complex to produce as the system itself. You will pay for those cheaper spare parts by higher wear, more working time and substandard welding results. Those are the facts.

Material Steel and st. steel

Thickn. mm Dia. mm 1.0 1.0-1.6 1.6 1.6-2.4 2.4-3.2 1.0 1.6 2.4 1.0 1.6 1.6 2.4 3.2 3.2

Ampere 10-60 40-80 70-120 90-150 140-180 60-80 100-150 150-180 10-60 40-80 70-120 90-150 140-180 170-180

Gas nozzle 4 5 5 6 7 4 5 6 4 5 5 6 7 7

TIG wearing parts To ensure optimum welding results, electrode diameters, welding current and gas nozzle must all be adjusted in line with the thickness. On the right is a table containing the relevant guideline values.

TIG torch for HT and HANDY-TIG Torch WLT 26DD, with 4 m hose set. Order no. 507.2640.0 (PG2) Torch WLT 26DD, with 8 m hose set. Order no. 507.2680.0 (PG2) TIG-UD torch with remote control only for the HT Torch WLT 26UD, with 4 m hose set. Order no. 507.2646.0 (PG2) Torch WLT 26UD, with 8 m hose set. Order no. 507.2686.0 (PG2)

1.0 1.5 2.0 3.0 4.0-6.0 Copper and 1.0 copper 1.5 alloys 3.0 Aluminium 1.0 1.5 2.0 3.0 4.0 5.0

Tungsten electrodes, gold New-style, lathanised, with excellent ignition properties. Long service life. Suitable for DC and AC. Environmentally friendly,100 % radiation free. Length: 175 mm. For matching diameters, see above table. Diameter 1.0 mm 1.6 mm 2.4 mm 3.2 mm Pack 10 pcs. 10 pcs. 5 pcs. 5 pcs. Order no. 535.8006.1 535.8006.2 535.8006.3 535.8006.4 PG2 PG2 PG2 PG2

Ceramic gas nozzles for TIG torch WLV/WLT17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 4 5 6 7 5 pcs. 5 pcs. 5 pcs. 5 pcs. PG2 PG2 PG2 PG2 535.8003.4 535.8003.5 535.8003.6 535.8003.7

Tungsten electrodes, green Pure tungsten, for welding aluminium materials with AC. Good arc shape, very stable arc. Not for DC. Length 175 mm. For matching diameters, see above table. Diameter Pack 1.0 mm 10 pcs.. 1.6 mm 10 pcs. 2.4 mm 5 pcs. 3.2 mm 5 pcs. Order no. 535.8005.1 535.8005.2 535.8005.3 535.8005.4

Collets for TIG torch WLV/WLT 17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 1.0 mm 1.6 mm 2.4 mm 3.2 mm 5 pcs. 5 pcs. 5 pcs. 5 pcs. PG2 PG2 PG2 PG2 535.8000.1 535.8000.2 535.8000.3 535.8000.4

PG2 PG2 PG2 PG2

Clamping cap WLV/WLT 17/26 short, for restricted space conditions. Order no. 535.8004.1 (PG2) Clamping cap WLV/WLT 17/26 long, standard torch cap, spare. Order no. 535.8004.2 (PG2)

Collet body for TIG torch WLV/WLT17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 1.0 mm 1.6 mm 2.4 mm 3.2 mm 24 2 pcs. 2 pcs. 2 pcs. 2 pcs. PG2 PG2 PG2 PG2 535.8001.1 535.8001.2 535.8001.3 535.8001.4

TIG accessory kit in case, for 2.4 mm- WLT 17/26, 3 collets and collet bodies, 5 ceram. gas nozzles size 6, 1 T electrode Order no. 551.3052.0 (PG2)

The Peak
Tungsten electrodes which are not pointed and precision ground develop magnetic disturbance. Ignition problems and a migrating arc are the result. IMPORTANT: The Lorch Teg 4.0. The tungsten carbide grinding machine. After all, you dont use an axe to sharpen your pencils. All electrode sizes with diameters of 1 to 4mm can be ground. Electrodes which are as short as 15mm, or are badly eroded or damaged with spatter, can be handled. Clear view of the grinding process. Diamond grinding wheels with 3 longlasting grinding surfaces. Adjusted by means of a handle. Precision grinding finish. Accurate electrode guidance. The grinding angle can be varied from 15 - 180. Only 0.3mm of material surface is removed. Grinding dust is removed by an integral filter unit, ensuring the health and safety of the operator. Speed infinitely variable 28,000 rev/min. power 850 W, 230 V, diamond wheel 40 mm dia., weight 2.8 kg. Complete assembly in a neat carrying case. Order no. 810.8600.0 (PG 12) Stationary arrest mechanism Order no. 810.8606.0(PG 12)

Grinding wheel dia. 40 mm Electrode holder Collet chuck dia. 1.0 mm Collet chuck dia. 1.6 mm Collet chuck dia. 2.0 mm Collet chuck dia. 2.4 mm Collet chuck dia. 3.2 mm Collet chuck dia. 4.0 mm Filter cassette Viewing window Disposable filter bag

Order no. 810.8601.0 810.8602.0 810.8603.0 810.8603.1 810.8603.2 810.8603.3 810.8603.4 810.8603.5 810.8604.0 810.8608.0 810.8605.0

PG 12 12 12 12 12 12 12 12 12 12 12

25

TIGknowledge

A very intense and focused arc is produced during TIG welding. The advantages are a minimum introduction of heat, narrow seam and welding without filler metals. Only the base material fuses with itself leading to perfect quality visible welds. Very small currents can be set with good TIG inverters, thus enabling the welding of very thin materials. Industry and trade have been making money with the advantages of TIG welding for a long time. Whenever demands such as leakproof, safe for foods, visible, etc. are placed on a weld seam, irrespective of whether stainless steel or aluminium are used, TIG is the solution. TIG machines used to be big and cumbersome. Moreover, their setting was complicated and their purchase price high. However, the increased use of stainless steel and aluminium means that metalworking companies are having to turn to TIG welding including on building sites.

TIG welding for you. Which is why we have developed our HANDY inverters to spare you any problems. Small, lightweight and handy. Therefore easy to use, because a lot of what you previously had to set has been integrated during their development as artificial intelligence. Each machine is designed for welding from a 230 V lighting mains. Since anything which is good sells easily, we have consistently been able to lower the price. But what do you get out of this technology? Mobility. For workshop and construction. Final assembly of stainless steel railings, aluminium facings and similar tasks can be performed outdoors without any problems. Nor do you have to mask off large areas, spattering is a thing of the past. Everything is lighter, smaller and easier to handle. Convincing advantages over the heavyweight rivals. You drastically reduce finishing work, because the look and quality of your seam is perfect. As we said: TIG earns you money.

What else do you have to know. There is a choice of DC and AC welding. DC welding is used for steel, stainless steel and copper, AC for aluminium and magnesium. A further important difference is the ignition method: you choose between noncontact HF ignition and contact ignition, also called lift-arc ignition. During contact ignition the tungsten electrode is placed on the workpiece - a low current flows, the system switches over to the welding current by raising the electrode slightly, the arc is ignited. The advantages of this method are a low purchase price and no interference with other electronic devices through HF. However, there is the risk that tungsten impurities will remain on the workpiece, which can lead to corrosion. During HF (= High-frequency) ignition the tungsten electrode is kept at a distance. Short HF pulses ionise the air gap between electrode and workpiece. The arc ignites. An absolutely professional ignition method. When all is said and done, anyone who does without TIG technology today is not doing himself a favour, because TIG welding has become simpler.

26

Another handy tip for everyday TIG welding A frequent mistake people make is incorrect handling of the tungsten electrode. With direct current (DC) welding, the electrode must be ground to a point lengthways relative to the current flow direction. Even grinding ridges should be polis-

hed away. Anyone omitting to do this will experience magnetic faults leading to considerable ignition problems and an instable light arc. For alternating current (AC) welding, up to a diameter of 1.6 m, electrodes do not require grinding, although for electrodes over this diameter, a chamfer is required, naturally also in the longitudinal direction.

This is the only way to ensure a narrow light arc and a neat seam which is not too wide. The Lorch Teg 4.0 tungsten electrode grinding machine is the ideal way to keep your electrodes in tip-top condition. Guaranteed to eliminate ignition problems and arc instability. For details, turn back a page.

Shielding gases used for TIG welding For all melting materials For all melting materials Argon 4.6 / 99.996% Argon Argon 4.8 / 100 % Argon I1 as per DIN EN 439 I1 as per DIN EN 439 I3 as per DIN EN 439

Nickel-based alloys, copper, aluminium argon-helium mixtures 30 % He, rest Argon 50 % He, rest Argon 70 % He, rest Argon

27

Anyone who needs to weld with 5 mm thick electrodes opts for the ISI. Switchover facility from 230 V to 400 V.
Electrode
TIG

28

ISI 5 CL There are lighter, smaller electrode inverters than the ISI 5 CL, some are even cheaper. But is there a better one? Order no. 115.0051.0 (PG12)

A milestone in the history of converter construction. The ISI 5 CL combines the ideals of electrode welding like no other machine we make. This inverter miracle has maximum voltage reserves thanks to the generously dimensioned Power-Mos power module and high-speed arc control, combined with a complex ripple filter. This all adds up to a very stable DC arc, which in turn means better welding than many others! Every location and position. Not forgetting the 6 selectable current programs, an extraordinary thin sheet pulse from 0.8 mm and a patented power circuit. This is very unusual for an inverter, but unbelievably useful: it allows you to switch from 230 to 400 V. A feature which knows no limits. Make it ISI buy ISI. Method Electrode diameter (electrode/TIG) Material Rec. material thickness (electrode/TIG) Welding range (electrode/TIG) Current at 60% duty cycle (25/40) Setting Mains voltage Electrode welding/TIG welding 1.5-5.0 mm/1.0-3.2 mm Steel/stainless steel up to12 mm/1-6 mm 3-200 A/3-220 A 200A/170A stepless 230/400V

Scope of delivery: Unit with mains cable with CEE-16 plug, mains adaptor 230V/400V with shock-proof plug, operating manual. High no-load voltage, infinitely variable current adjustment, 6 different welding programs: normal, soft, hot start 1 + 2, arc-force, thin sheet pulse. Dropped seam-proof, patented mains switchover 1~230 V/3~400 V, compensation of mains fluctuations, remotecontrollable. S mark, approved for use in small rooms with a higher electrical risk, sturdy construction with a dust-proof encapsulated control area, conforms with EN 60974-1, CE mark. TIG welding with additional TIG valve torch and pressure reducer: manual gas control via valve in torch handle. Accessories Welding accessories SPA 35 mm2/ plug 13, professional welding equipment, 35mm highly flexible welding cable (2 x 4 m) with electrode holder and ground clamp, protection shield EN 166, welding glasses DIN 4646-47, wire brush and slag hammer Order no. 550.5504.0 (PG14) Transportation belt Simplifies transport on site. Complete set with fixings. Order no. 570.4100.0 (PG12) Hand remote control HR 30 for remote adjustment of the welding current, complete with 5 m lead. Order no. 570.1031.0 (PG14) Extension cable set complete with cable plug and socket. For extending the hand remote control lead. KSF 75, 7.5 m long, Order no. 570.9033.0 (PG14) KSF 150, 15 m long, Order no. 570.9036.0 (PG14) Accessories for TIG on page 41 29

What you need for TIG welding TIG lift arc set WLV 26/3550, comprising TIG valve torch WLV 26, 4 m; tungsten electrode 2.4 mm, pressure reducer with volume and content manometer. Order no. 104.9005.0 (PG12)

Revered as a legend among welding machines. The CL.

Electrode

30

CL 4 P-F just

CL 5 P-F just

Our classics. A blueprint for our rivals and equipment used by over 100,000 men on this continent. For business, workshop and building site to date we have built a total of 177,021 units. However legends only arise by constantly paying tribute to the truth. This, as we all know, is found on the inside of welding machines. Ours contain all of our experience. It would have been stupid to alter the housing, you would only have had to pay for this, and it would only have misled you. Because theres nothing wrong with the ergonomics and a fibreglass-reinforced polyester housing is indestructible, never rusts and is fully insulated. The housing will never be live in the event of defects or if dropped or incorrectly connected on building sites. The CL today is as good as it ever was. As the transformer and inductor are of copper, the only way to achieve the right ignition and welding properties. The working point can be ideally set for both machines. This is guaranteed by 11 settings for the CL 4 P-F and an infinitely adjustable control with toroidal core inductor in the CL 5 P-F. This allows a fast and comfortable adjustment to changing welding positions. The excellent duty cycles are achieved with a powerful intensive fan cooler. The ergonomically arranged controls are always within reach and easy to read from a distance. The thermocontrol, an overload protection with warning display, provides additional safety. Every CL can be switched over from 230 V lighting mains to 400 V 3-phase mains and the welding cables can be removed with a quick-action coupler. We hope that this meets all of your needs.

CL 4 P-F Method Electrode diameter Material Rec. material thickness Welding range Duty cycle at max. current (25/40) Current at 60% duty cycle (25/40) Settings Mains voltage Order no. (PG 12) Electrode welding 1.5-4.0 mm Steel/stainless steel 1-10 mm 20-175 A 60 % /40 % 175 A /145 A 11 230/400 V 106.5005.0

CL 5 P-F Electrode welding 1.5-5.0 mm Steel/stainless steel 1-12 mm 25-200 A 60 % /40 % 200 A /170 A Infinitely variable welding current setting in a single revolution 230/400 V 106.5007.0

Scope of delivery: Unit with mains cable with CEE-16 plug, mains adaptor 230 V/400 V with shock-proof plug, operating manual.

To match: Complete set of welding accessories. SPA 25 mm / plug 13, professional welding accessories 25 mm2, highly flexible welding cable (4 m + 3 m) with electrode holder and ground clamp, protection shield EN 166, welding glasses DIN 4646/4647, wire brush and slag hammer, order no. 550.5503.0 (PG 14)
2

31

Important! Wh of weld seam

Labour
Wages and salaries account for 76 cm of the overall costs

32

h at does 1metre really cost?

Gas
9 cm

Electric Wire power 6 cm

4 cm

Unit
5 cm is what your welding unit costs. Acquisition, depreciation, interest.

This is something we should all give some thought to. Compared to the costs of labour, fuel and consumables, the purchase of a new welding unit pales into insignificance. But the tendency is to concentrate on the price of the machine and forget what happens next. Particularly if we look at labour costs, which can be pushed through the roof by choosing the wrong, cheap welding equipment. Think about it: At Lorch we build welding machines designed to make your work and your life easier. And for this we charge you a whole 5 cm.

Realistically 76 cm working time As a rule, a talented welder will put in a good 1,907 hours a year. If he uses a less talented welding unit which reduces his work input by just 8%, that makes 152.56 hours lost. But if we assume an hourly wage of 17.90 an, that adds up to 2,730.80 every year. And the fact that this type of welding equipment is written off on average over five years means the whole deal will cost you 13,654.-- on top. Not to mention the effect on your nerves.

So perhaps now you are closer to understanding a typical Lorch precept: Better good and sound than bad and unreliable.

33

One for all

TIG MIG-MAG Electrode
MIG-brazing

34

The A and the ACuSi. All in one. 3 steps to perfect welding. SmartBase guides you easily through all tasks. Up to 4 processes run easily through your hand.
Faster, more mobile, lighter and better than the rest. Once you own one of the new A series from Lorch, you will be able to forget needing a B or indeed any other system. Because these models will supply you with the perfect workshop MIG-MAG unit which you can take around and about with you without even thinking. 19 kg of high-end inverter technology certainly wont weigh you down. And it can withstand some pretty rough treatment. In the past there were two options when it came to working on site: Either costly welding using electrodes which meant swallowing higher additional material costs, more work chipping slag and slower welding speeds - or else the inconvenience of lugging a heavy workshop unit or even the precious pulse inverter with you. The tough competitive climate means you cant afford option one, option two is impracticable. Which as far as we are concerned, just leaves the A. Really good MIG-MAG welding with infinitely variable adjustment from bottom to top. The wire speed is automatically adjusted. Steel, stainless steel or aluminium. Really good MIG-MAG welding without gas. Thanks to its amazingly simple equipment, MIG-MAG welding works in the open air using gasless wire. Just like a normal wire spool. Forget scaling the scaffolding clutching a gas cylinder. These wires contain a special powder which generates gas and slag in the same way as with electrode welding. Really good TIG welding. Outstanding ignition and welding characteristics for TIG-DC with steel and stainless steel. Really good electrode welding. The welding characteristics are perfect for electrode welding too. Because of the high output, the A 1700 is easily capable of welding with 4 mm electrodes. And the A 2200 even copes with 5 mm electrodes. And with the ACuSi: Really good MIG brazing. At long last here is a method of professionally joining galvanised and steel sheet without damaging the corrosion protection. MIG brazing is a process which takes place only at 800C. Minimal heat, negligible voltage, practically no distortion. And the ACuSi is ideal for use on brazing robots too. Infinitely variable MIG-MAG inductor for steel stainless steel aluminium Intervention in the automatic system for individual fine tuning

3.
Current and voltage setting digitally displayed

Precision wire speed adjustment For TIG down-slope Digitally displayed

1.
Select MIG-MAG, TIG electrode TIG 2Press once for stroke Spots slower up-slope and down-slope, 4Interval Select perfect seam start stroke no end craters diameter of with TIG welding wire pulsing tungsten needle stick electrode

2.

35

The A offer TIG, MAG-MAG and electrode

A 1700 0.8 wire MIG-MAG, 150 A TIG, electrode 4 mm. 230V. 19 kg on site Order no. 201.1700.0 (PG 12)

A 2200 1.0 wire MIG-MAG, 200 A TIG, electrode 5 mm. 230/400V. 20 kg on site Order no. 201.2200.0 (PG 12)

A
Welding range MIG-MAG infinitely variable DC at max. current (40) Current at 60 % DC (40 ) Mains voltage Weldable wires steel/aluminium Material MIG-MAG Recommended material thickness steel / aluminium Welding range TIG/electrode DC at max. current (40) TIG/electrode Current at 60 % DC (40 ) TIG/electrode Electrode diameter TIG/electrode Weldable material TIG/electrode Recommended material thickness for TIG Recommended material thickness for electrode Weight

MIG-MAG without gas. These wires contain a special powder which generates gas and slag. A simple resetting job.

A 1700 A 2200 35 - 170 A 35 220 A 25 % / 170 A 15 % / 220 A 120 A 170 A 230 V 230 V / 400 V 1 Ph 0.6-0.8 mm / 1.0 mm 0.6-1.0 mm / 1.0 mm Steel / stainless steel / aluminium 0.8-5 mm / 2-3 mm 0.88 mm / 2-5 mm 5150/25-150A 5-200/25-200A 35 %/30 % 35 %/30% 130/120 A 170/170 A 1.0-2.4/1.5-3.25 mm 1.0-3.25 mm/1.5-5.0 mm Steel, stainless steel, with TIG also copper 1-4mm/copper 1-3 mm 1-6 mm/copper 1-4 mm up to 10 mm up to 12 mm 19 kg 20 kg

Scope of delivery: Torch ML 1500, 4 m Torch ML 2400, 4 m Shock-proof plug, Shock-proof plug, CEE-32 plug Ground cable 25 mm2, 4 m; pressure reducer, basket coil adapator, mains cable 4 m, gas hose.

36

The A offer TIG, MIG-MAG, electrode and MIG-brazing

A 1700 CuSi 0.8 wire MIG-MAG, 150 A TIG, electrode 4 mm. 230 V. 19 kg on site. Order no. 201.1710.0 (PG 12)

A 2200 CuSi 1,0 wire MIG-MAG, 220 A TIG, electrode 5 mm. 230/400 V on site. Order no. 201.2210.0 (PG12)

ACuSi
Welding range MIG-MAG infinitely variable DC at max. current (40) Current at 60 % DC (40 ) Mains voltage Weldable wires steel/aluminium Material MIG-MAG Recommended material thickness steel / aluminium Welding range TIG/electrode DC at max. current (40) TIG/electrode Current at 60 % DC (40 ) TIG/electrode Electrode diameter TIG/electrode Weldable material TIG/electrode Recommended material thickness for TIG Recommended material thickness for electrode Weight A 1700 CuSi A 2200 CuSi 35 220 A 35 - 170 A 25 % / 170 A 15 % / 220 A 120 A 170 A 230 V 230 V / 400 V 1 Ph 0.6-0.8 mm / 1.0 mm 0.6-1.0 mm / 1.0 mm Steel / stainless steel / aluminium 0.8-5 mm / 2-3 mm 0.88 mm / 2-5 mm 5150/25-150A 5-200/25-200A 35 %/30 % 35 %/30% 130/120 A 170/170 A 1.0-2.4/1.5-3.25 mm 1.0-3.25 mm/1.5-5.0 mm Steel, stainless steel, with TIG also copper 1-4mm/copper 1-3 mm 1-6 mm/copper 1-4 mm up to 10 mm up to 12 mm 19 kg 20 kg

Scope of delivery: Torch ML 1500, 4 m Torch ML 2400, 4 m Shock-proof plug, Shock-proof plug, CEE-32 plug Ground cable 25 mm2, 4 m; pressure reducer, basket coil adapator, mains cable 4 m, gas hose.

37

MIG-MAG accessories A 1700, A 2200 and CuSi

Ergonomics, a highly flexible hose set, wear-proof torch neck and optimum current transmission all interact in these torches to ensure optimum welding characteristics and a service life that pays dividends. A 1700 torch ML 1500, 3 m long, order no. 503.1500.3 (PG2) ML 1500, 4 m long, order no. 503.1500.4 (PG2) When using for MIG brazing, brazing torch set order no. 551.2015.0 is additionally required A 2200 torch ML 2400, 3 m long, order no. 503.2400.3 (PG2) ML 2400, 4 m long, order no. 503.2400.4 (PG2) When using for MIG brazing, brazing torch set order no. 551.2015.0 is additionally required Liners ML 1500, ML 1500 PM Liners ML 2400, ML 2400 PM Liner for steel wire 0.6 - 0.9 mm, colour code blue For 3 m torch, (PG02), order no. 535.8300.1 For 4 m torch, (PG02), order no. 535.8300.2 Liner for steel wire 1.0 - 1.2 mm, colour code red For 3 m torch, (PG02), order no. 535.8300.3 For 4 m torch, (PG02), order no. 535.8300.4 Conversion kit aluminium, 1.0 or 1.2 mm. Combination teflon liner with flangemounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. For torches up to 4 m. Order no. 551.2014.0 (PG2) Conversion kit stainless steel, 0.6/0.8/1.0 mm Combination carbon - teflon liner with flange-mounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. For torches up to 5 m. Order no. 551.2015.0 (PG2)

A 1700 PowerMaster torch ML 1500 PM, 3 m long, order no. 503.1501.3 (PG2) ML 1500 PM, 4 m long, order no. 503.1501.4 (PG2) When using for MIG brazing, brazing torch set order no. 551.2015.0 is additionally required A 2200 PowerMaster torch ML 2400 PM, 3 m long, order no. 503.2401.3 (PG2) ML 2400 PM, 4 m long, order no. 503.2401.4 (PG2) When using for MIG brazing, brazing torch set order no. 551.2015.0 is additionally required

PowerMaster torch. Regulate power and speed by remote control in the torch itself.

Contact tips for torch, ML 1500 + ML 1500 PM, PG2 Design Pack Order no. 0.6 mm M6 5 535.8101.1 0.8 mm M6 5 535.8101.2 1.0 mm M6 5 535.8101.3 For aluminium wire 1.0 mm M6 5 535.8101.5 1.2 mm M6 5 535.8101.6 Contact tips for torch, ML 2400 + 2400 PM, PG2 0.6 mm M6 5 535.8106.1 0.8 mm M6 5 535.8106.2 1.0 mm M6 5 535.8106.3 For aluminium wire 1.0 mm M6 5 535.8106.5 1.2 mm M6 5 535.8106.6 Retaining springs for gas nozzles, PG2 For ML 1500 + PM 10 535.8100.9 Contact tip holders, PG2 For ML 2400 + PM 2 535.8120.4 Gas diffuser, PG2 2 535.8120.3 For ML 2400 + PM Plug-in gas nozzles, for torch ML 1500 + PM, PG2 Tapered gas nozzle 3 535.8100.1 Cylindrical gas nozzle 3 535.8100.2 Spot gas welding nozzle 3 535.8100.3 Plug-in gas nozzles, for torch ML 2400 + PM, PG2 Tapered gas nozzle 3 535.8120.1 Cylindrical gas nozzle 3 535.8120.2

38

Original equipment kit for torch ML 1500, 3 m Kit including the most important torch wearing parts at an affordable all-in price. Contains: 1 tapered gas nozzle, 1 spot gas welding nozzle, 5 contact tips 0.8 mm, 1 liner blue 0.6-0.9 mm, 3 retaining springs, 1 Lorch separating spray 400 ml. Order no. 551.1021.0 (PG2) Original equipment kit for torch ML 2400, 3 m Kit including the most important torch wearing parts at an affordable all-in price. Contains: 1 tapered gas nozzle, 1 spot gas welding nozzle, 5 contact tips 1.0 mm, 1 liner red 1.0-1.2 mm, 1 contact tip holder, 1 Lorch separating spray 400 ml. Order no. 551.1024.0 (PG2)

MIG-MAG welding wire SG2, 0.8 mm for welding unalloyed steel. Small spool D200, 5 kg, Order no. 590.0008.1 (PG12) SG2, 0.8 mm for welding unalloyed steel. Standard spool K300, 15 kg, Order no. 590.0008.6 (PG12) SG2, 1.0 mm for welding unalloyed steel. Standard spool K300, 15 kg, Order no. 590.0010.4 (PG12) AlMg5, 1.0 mm for welding aluminium. Small spool D200, 2.0 kg, Order no. 590.0410.0 (PG12) AlMg5, 1.2 mm for welding aluminium. Small spool D200, 2.0 kg, Order no. 590.0412.0 (PG12) 1.4316, 0.8 mm for welding stainless steel (V2A). Small spool D200, 5.0 kg, Order no. 590.0208.1 (PG12) Cored wire for welding without shielding gas 0.9 mm dia. For low-alloyed sheet materials up to 15 mm. Small spool D 200, 4.5 kg Order no. 590.0200.9 (PG 12)

Torch original equipment kit Containing the different accessory kits - but packaged safely and neatly in a sturdy plastic case with handy compartments Order no. 551.0490.1 (PG12) for ML 1500, just Order no. 551.0490.3 (PG12) for ML 2400

Set of torch wearing parts for ML 1500 Case containing the following main wearing parts. 3 tapered gas nozzles, 10 contact tips 0.8 mm, 10 retaining springs. Order no. 551.1508.0 (PG12)

Set of torch wearing parts for ML 2400 Case containing the following main wearing parts : 3 tapered gas nozzles, 10 contact tips 1.0 mm, Order no. 551.2524.0 (PG12)

High-grade brazing wires ACuSi CuSi3-wire for galvanised sheet 0.8 mm, small spool D200, 5 kg, order no. 590.1008.1 (PG 12) 0.8 mm, basket coil K300, 15 kg, order no. 590.1008.3 (PG 12) 1.0 mm, small spool D200, 5 kg, order no. 590.1010.1 (PG 12) 1.0 mm, basket coil K300, 15 kg, order no. 590.1010.3 (PG 12) CuAl8 wire for stainless steel 0.8 mm, small spool D200, 5 kg, order no. 590.1108.1 (PG 12) 0.8 mm, basket coil K300, 15 kg, order no. 590.1108.3 (PG 12) 1.0 mm, small spool D200, 5 kg, order no. 590.1110.1 (PG 12) 1.0 mm, basket coil K300, 15 kg, order no. 590.1110.3 (PG 12)

39

MIG-MAG accessories A 1700, A 2200 and CuSi

The original Lorch torch and original Lorch spares are essential components of an A. There are people who think it is a good idea to produce copies of them. At first glance, you may well save a good 20 - 40% by buying these counterfeit copies. But you can rest assured they are made of cheaper basic materials. Otherwise there would be no profit margin for the plagiarists. After all, our spare parts are just as valuable and complex to produce as the system itself. Adaptor for basket coils K300 Included in the scope of supply of the A models. Spares: Order no. 551.9020.0 (PG12) Adaptor for small spools For using plastic spools with a 200 mm diameter. Spacer guarantees reliable wire feed. Order no. 620.9650.0 (PG 12) Feed rolls A 1700 and A 2200 For steel/stainless steel wires 0.6 / 0.8 mm Order no. 620.8700.0 (PG12) For steel/stainless steel wires 0.8 / 1.0 mm Order no. 620.8701.0 (PG12) For steel/stainless steel wires 1.0 / 1.2 mm Order no. 620.8710.0 (PG12) For Aluminium and brazing wires 0,8/1,0 mm Order no. 620.8701.1 (PG 12) For aluminium wires 1.0 /1.2 mm Order no. 620.8710.1 (PG12) Lorch separating spray 400 ml Forms a thin protective film in the gas nozzle to protect against sintering of hot weld splashes. Order no. 551.9000.0 (PG2)

Ground cables With ground clamp and plug. Another case where quality counts. Steady, reliable current transmission is imperative to a neat, tidy job. Defective or worn ground cables really do have to be replaced. A 1700 and A 2500 25mm2, 4m, plug 13mm, Order no.551.0120.0 Autoprotect X 10+11, protective level DIN 10. Converts to DIN 11. MIG-MAG/electrodes welding. Order no. 550.5311.0 (PG12) Autoprotect Flex 9-13, protective level DIN 9 to 13. Electrode/ MIG-MAG/TIG. Dark/light switching. Sensor bar. Order no. 550.5312.0 (PG12) Autoprotect Multiflex 5-13 protective level DIN 5 to 13. Electrode/ MIG-MAG/TIG. Daylight filter, sensitivity regulator. Keeps going where other helmets give up the ghost. Order no. 550.5313.0 (PG12)

MIG-MAG protective gloves Made of high-grade, durable leather. With wear-resistant seam. What a real welders glove should look like. Order no. 535.8210.0, (PG12)

Special pliers MIG-MAG 4 functions. Cutting the welding wire. Cleaning the shielding gas nozzle. Pulling off the gas nozzle. Releasing the contact tip. Order no. 535.8225.1 (PG12) Electrode welding cable with electrode holder 25 mm2, 4 m long, with electrode holder and 13 mm connecting plug. Is required to weld electrodes. Order no. 551.0220.0 (PG 14)

40

TIG accessories A 1700, A 2200, and CuSi

The electrode diameter, welding current and gas nozzle should be adapted to the material thickness. See the table below.

Material Steel and st. steel

Thickn.

Dia. mm 1.0 1.0-1.6 1.6 1.6-2.4 2.4-3.2 1.0 1.6 2.4 1.0 1.6 1.6 2.4 3.2 3.2

Ampere 10-60 40-80 70-120 90-150 140-180 60-80 100-150 150-180 10-60 40-80 70-120 90-150 140-180 170-180

Gas nozzle 4 5 5 6 7 4 5 6 4 5 5 6 7 7

Collet body for TIG torch WLV/WLT 17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 1.0 mm 1.6 mm 2.4 mm 3.2 mm 2 pcs. 2 pcs. 2 pcs. 2 pcs. PG2 PG2 PG2 PG2 535.8001.1 535.8001.2 535.8001.3 535.8001.4

1.0 1.5 2.0 3.0 4.0-6.0 Copper and 1.0 copper 1.5 alloys 3.0 Aluminium 1.0 1.5 2.0 3.0 4.0 5.0

TIG torch for the A 1700 Torch WLT 17EA, with 4 m hose set. Order no. 507.1460.4 (PG2) Torch WLT 17EA, with 8 m hose set. Order no. 507.1460.8 (PG2) TIG torch for the A 1700 Torch WLT 26EA, with 4 m hose set. Order no. 507.2660.4 (PG2) Torch WLT 26EA, with 8 m hose set. Order no. 507.2660.8 (PG2)

Tungsten electrodes, gold New-style, lathanised, with excellent ignition properties. Long service life. Suitable for DC and AC. Environmentally friendly,100 % radiation free. Length: 175 mm. For matching diameters, see above table. Diameter 1.0 mm 1.6 mm 2.4 mm 3.2 mm Pack 10 pcs. 10 pcs. 5 pcs. 5 pcs. Order no. 535.8006.1 535.8006.2 535.8006.3 535.8006.4

TIG welding rods are what make the actual joint.

PG2 PG2 PG2 PG2

Clamping cap WLV/WLT 17/26 short, for restricted space conditions. Order no. 535.8004.1 (PG2) Clamping cap WLV/WLT 17/26 long, standard torch cap, spare. Order no. 535.8004.2 (PG2)

Stainless steel 1.4576 Filler metal for welding unstabilised and stabilised corrosionproof Cr Ni-Mo steels for operating temperatures up to appr. 400C. Suitable for base materials 1.4401, 1.4404, 1.4435, 1.4436, 1.4437, 1.4571, 1.4573, 1.4480, 1.4581, 1.4583 50 rods, 1.6 mm, order no. 590.5416.3, (PG 12) 50 rods, 2.0 mm, order no. 590.5420.3, (PG 12) Stainless steel 1.4370 Filler metal for joints between non-alloyed and low-alloyed steels for operating temperatures up to appr. 300C, cold tough to appr. 120C. Suitable for joints between e.g. St 37-3 and 1.4301. 50 rods, 1.6 mm, order no. 590.5816.3, (PG 12) 50 rods, 2.0 mm, order no. 590.5820.3,(PG 12)

Ceramic gas nozzles for TIG torch WLV/WLT 17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 4 5 6 7 5 pcs. 5 pcs. 5 pcs. 5 pcs. PG2 PG2 PG2 PG2 535.8003.4 535.8003.5 535.8003.6 535.8003.7

Collets for TIG torch WLV/WLT 17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 1.0 mm 1.6 mm 2.4 mm 3.2 mm 5 pcs. 5 pcs. 5 pcs. 5 pcs. PG2 PG2 PG2 PG2 535.8000.1 535.8000.2 535.8000.3 535.8000.4

TIG accessory kit 1 in case, for 1.6 mm WLT 17/26, 3 Collets and collet bodies, 5 ceramic gas nozzles size 5, 1 T electrode Order no. 551.3051.0 (PG2) TIG accessory kit 2 in case, for 2.4 mm- WLT 17/26, 3 collets and collet bodies, 5 ceram. gas nozzles size 6, 1 T electrode Order no. 551.3052.0 (PG2)

41

Discount it!

Right then. You have really decided to buy

yourself a welding system. Great. Question is - which one? Sales people will promise you never even held a welding torch. How can they possibly offer you any sensible advice? Like someone without a licence giving an expert opinion about cars. the world. Rumour has it some of them have

Read befor % B C
Brand quality
The tendency in this category is for manufacturers to have nothing but the rating plate

Brand quality

made in Germany. Everything else comes

from all over the place. This is how B quality

So from now on you will place your trust in good, solid brand names. A product that has been around a long time cant be all bad. Or can it? You are bound to know lousy business people who have been around forever against all the odds. Sometimes investors can find themselves paying just for a label. They pay no attention to the inner values of nities and what not are all more important. So as not to confuse you completely, let us just say two sentences thing about C brand quality: It comes from outside of Europe,

brand systems are produced today. They are 300 Euros cheaper, they weld - and the housing looks highly professional. The apprentice will just love it. But it is in the fine tuning that everything falls apart. The specified amperage loses all credibility after warm-up, and certainly defies any sensible measurement. Just one example: The latest B systems Chechnya. Unable to believe the price, we got hold of one. Once we opened it up, all was revealed. Simplistic technology. Set to age in a few months at the outside. Sending the wire feed off balance, causing the free burn time of 20/100th of a sec. to shoot to 0.5 secs., meaning a continuous problem with nozzle burnout. So you limp along for another 2 or 3 years until one day: total failure. Part price just 100 Euros. Telephone call 2 Euros. Outage 10 days. But then, you did pay a whole 198 Euros less to start with. No. In actual fact the work quality and time lost with this stone age technology has already cost you a lot more than you realise.

their purchase. Market share, sales opportu- come with low-cost control systems from

These are the types you will encounter mostly where everything revolves around price. This is where you will see those tempting offers. X Euros! and a money back guarantee if undersold. So you buy. You take it home and you start welding. The seam stays in one piece, and from that day forward you firmly believe that this is how a welding system is simply meant to be. It stutters its way through life. But then, you paid just 1,000 Euros. Actually you were relieved of 1,000 Euros. The follow-up costs can mount alarmingly if you work with it professionally. The thing is useless and good only for the scrap heap. This is known as the % category. Now you realise there must be real brand names around too. And there are.

and the lions share of the costs you pay goes towards sales commission and freight. Dont be surprised to see a white elephant walking past your workshop.

42

ore you buy

Recommendation: As far as we are concerned, in Germany there are three welding system producers you can safely buy from if work quality, satisfaction, durability and added value mean anything to you. One of those is Lorch. German made through and trough. And so we move on to an impressive name right off the top of the A list. As early as the companys foundation in 1957, development was the future. The photo showing strength testing by standing a truck on a polyester housing, gives you some idea of how things were

Brand quality
to developing a new welding system to bentechnology team have free rein. As much material as they need. Time too. Which there is plenty of in tiny Auenwald. From the concept to the analogue and digital circuits, from the system software to that one essential screw - everything is created here. Because only what we build ourselves can we be sure will work. And what we dont know, we fetch home to Auenwald

But maybe the secret lies in the production, too. Only recently an automatic coating plant was introduced for electronic systems which is faster than anything before it. The Lorch gang worked for a whole month to slow it down. We need say no more about quality. The manufacture of a Lorch system is something that just wont be rushed. If we used more housings made of plastic, we could cut 21 minutes off the assembly time. But we stick with steel and with staff who understand about assembly precision - not everybody does. All dealer orders and queries are processed online. All requests are answered. Final inspection is fully computer automated. The Lorch high-bay warehouse is linked to the outside world by bar code. But when it

seen as the number one foundation stone for efit users, our engineers and application

done back then. Positive scepticism has been ingrained in the Lorch gang ever since. By far and away the first to introduce plastic housings to the market back then. Other manufacturers are still claiming this as highly innovative today. But things look very with the cooperation of universities and specialist institutes. In the beginning is always the idea. Followed by electronic tests and fundamental experiments, then the prototype. Which is when the going gets tough. Modify. Weld. Modify. Weld. Around the clock. For weeks. Finally whole different at Lorch in the 21st century. South German Auenwald is home to what must be systems end up on the scrap heap. Sometimes even whole projects. The sys-

comes to production itself, tradition is king. You could call it painstaking precision - and it is precisely this that makes a Lorch system better than anything else you can buy. But in the final reckoning, there is one main beneficiary in all this: You. And you will go on reaping the benefits for years to come. One of Lorchs fundamental principles: In Auenwald, nobody tells lies.

Europes most modern welding system facto- tems which demonstrate the greatest level of success under development are prory. Logistics pure. But one thing has not changed: Everyone is still preoccupied with welding. And the heady enthusiasm of those duced and launched into the marketplace. Where they hardly ever meet their match

early pioneers has never left. When it comes among comparable products of their day. 43

MIG-MAG

M stands for masterpiece. The 2000 series.

44

The 2nd M series has taken on a cult status. The MIG-MAG welding system for thin sheet and lightweight steel construction.

Why is it exactly that the world and its wife would rather be driving a Mercedes than an Opel? Looks better? More status? Is that all? Just ask a taxi driver. A cabby will make a professional judgement based on hard business sense. After all, he drives it. Or why is it that a hammer drill will slice through the concrete in just 3 seconds where others plug away for 15 seconds to make the same sized hole? Nobody who drills for a living would put themselves through that. It is no different if you look at our M system. If you are a professional you have no choice but to opt for this degree of MIG-MAG perfection. An amateur who does the odd bit of welding can save a good 400 Euros by shopping around for some sort of welding system. We dont supply this particular market and we never will. An M from Lorch offers inner values - values we set out to achieve at an enormous cost in terms of time and effort.

This type of behaviour can drive a professional welder round the bend. An M will go on giving just what we promise it will after hours. And years. Example 2 It is generally true that the sum of all details is what sets an object apart from the rest. Take a look at just one such detail - the knob next to the wire insertion. This is something you will be lucky to find on any other unit. But actually it is an ingenious detail. It allows you to insert the wire without picking up the torch. This unassuming looking knob is used to switch the wire feed then and there. Without it, the whole process becomes an imprecise science as your eyes move backwards and forwards between the torch switch and the wire feed roll. This knob with its surround costs us around 12 Euros. Others dont bother with it, although they are perfectly aware of its benefits. Savings like this allow them to shave more off the purchase price. Good for them.

Still a bit hit and miss, but cheap. And with a professional look. Great. True, they do brake the unit on a sloping workshop floor. But then there is the braked swivel caster you see here. You will find it under every single M. Expensive, but worth it. Guaranteed to stay solid as a rock in your trailer at the back. If you dont want your precious unit to fly off you had better tie it down. Example 4 The easiest way to fool the average craftsman is by palming him off with a cheap control system. Why? Because it costs a fraction and looks just the same. But after just a short time these cheap imitations will show signs of wear and tear. Your wire feed is thrown off balance, resulting in a shift in the free burning time. The result: nozzle burnout. The best bit: At first you assume that you are at fault. You never really realise what is going on. Even when the whole control system packs up within four years at the outside. 80% of all systems offered in the marketplace today fall under this category. Every M comes with a microcontroller. No wear. Precise, digital control of every single function. Our industrial systems all work to this high engineering standard. The best currently available. So you see - there are welding systems and welding systems. The choice is yours.

Example 3 Underneath every welding system are casters. Available to manufacturers in different qualities ranging in price from 10 Euros for a set of four up to 98 Euros. The question every producer asks is: How much do I invest in the bit you dont see? Most decide this is a place they can afford to cut Example 1 corners. Of course they roll. But efficient 90 % of all welding systems fall short of the braking is quite a different matter. And they specified output level once they have completed the warm-up phase. If the rating plate struggle over obstacles and around corners. says 350 amperes, chances are that will only At Auenwald, these are the sort we mount apply to a cold start. After just 5 minutes, the under our waste paper bins. We dont see any other valuable purpose for them. The other output takes a nose dive - but stealthily. In group among our competitors opt for casters other words while you are welding. with a kick-stop brake.

45

The basis of every M. From the 2020 to the 2095. 6 output models from 140 to 350 ampere. With up to 24 settings. Also with 4-roll drive. Lid opening to the side for improved access. Fully insulated inner floor to protect the welding wire basket against phase to ground short circuits. Absolute feed precision - more accurate pressure setting, no wire deformation, precise wire alignment and wire transport. Special wire inlet guides made of moulded brass to ensure easier running for steel and stainless steel as well as aluminium. Sophisticated electronics, compact central torch connection, adjustable wire roll brake, even easier operation and new, ergonomic outside front. A transformer-inductor combination which is of course copper-wound and ideally matched. A sturdy diode rectifier with overvoltage protection. Switching stages for optimum working points in every position. MIG-MAG logic, which controls the electronic welding current, feed, wire burn-back, gas postflow and spot welding time. Fully adjustable spot welding time. Air cooling for a higher duty cycle. Thermocontrol as overload protection. Horizontal wire spool take-up, suitable for large and small spools with no extra adaptor. Removable ground cable with quick-action coupler. Galvanised sheet steel housing with powder-coated front and sides. Integrated gas cylinder holder and compliance with the standards EN 60974-1 a, CE and S marks.

MIG-MAG

M 2020 All accessories included

Ideal for thin-sheet welding e.g. on vehicles Method Welding range Settings MIG-MAG welding 30-140 A 6

M 2040 All accessories included

Ideal for thin-sheet welding and profile work MIG-MAG welding 25 -170 A 6 25 % /15 % 90 A/70 A 0.6-0.8 mm 1.0 mm 230 / 400 V Steel/stainless steel/aluminium 0.8-5 mm 2-3 mm 0.6 mm /0.8 mm 202.2040.1

M 2060 All accessories included

Ideal for thin-sheet welding and light steel work MIG-MAG welding 25 - 210 A 6 25 % /15 % 105 A/85 A 0.6-1.0 mm 1.0-1.2 mm 230/ 400 V Steel/stainless steel/aluminium 0.8-8 mm 2-5 mm 0.6 mm /0.8 mm 202.2060.1

Duty cycle at max. current (25/40) 25 % /15 % Welding current at 100% DC (25/40) 70 A/55 A Weldable wires, steel Weldable wires, aluminium Mains voltage Material Material thickness, steel Material thickness, aluminium Set wire diameter Order number (PG12) Scope of delivery: 0.6-0.8 mm 1.0 mm 230 V Steel/stainless steel/aluminium 0.8-3 mm 2 mm 0.6 mm /0.8 mm 202.2020.1

System complete with torch System complete with torch ML 1500, System complete with torch ML 1500, ML 1500, 3 m; ground cable 3 m; ground cable 25 mm2, 4 m, 3 m (torch ML 2500 for top 25 mm2, 4 m, pressure reducer with pressure reducer with volume and performance range), ground volume and content manometer, content manometer, mains cable 4 m with cable 25mm2, 4m, pressure reducer with mains cable 4 m with schock-proof plug, CEE16-plug, mains adaptor 230V/400V volume and content manometer, mains cable fitted gas hose, with schock-proof plug, fitted gas 4 m with CEE 16-plug, mains adaptor operating manual. hose, operating manual. 230V/400V with schock-proof plug, fitted New: with basket coil adaptor New: with basket coil adaptor gas hose, operating manual. as standard. as standard. New: with basket coil adaptor as standard.

46

M 2080 All accessories included

All-round system for sheet and light to medium steel work MIG-MAG welding 30 - 230 A 7 30 % /20 % 140 A/115 A 0.6-1.0 mm 1.0-1.2 mm 400 V Steel/stainless steel/aluminium 0.8-10 mm 2-6 mm 0.8 mm /1.0 mm 202.2080.1 System complete with torch ML 2500, 3 m; ground cable 25 mm2, 4 m, pressure reducer with volume and content manometer, mains cable 4 m with CEE 16-plug, fitted gas hose, operating manual. New: with basket coil adaptor as standard.

M 2090, with 4-roll feed All accessories included

All-round system for sheet and medium steel work MIG-MAG welding 30 - 290 A 12 30 % /20 % 160 A/135 A 0.6-1.2 mm 1.0-1.2 mm 400 V Steel/stainless steel/aluminium 0.8-12 mm 2-8 mm 0.8 mm /1.0 mm 202.2090.1 System complete with torch ML 2500, 3 m, ground cable 25 mm2, 4 m, pressure reducer with volume and content manometer, mains cable 4 m with CEE 16-plug, fitted gas hose, operating manual. New: with basket coil adaptor as standard.

M 2095, with 4-roll feed All accessories included

All-round system for sheet and medium steel work MIG-MAG welding 25 - 350 A 24 30 % /20% 185 A/160 A 0.6-1.2 mm 1.0-1.6 mm 400 V Steel/stainless steel/aluminium 0.8-15 mm 2-12 mm 0.8 mm /1.0 mm 202.2095.1 System complete with torch ML 3600, 3 m; ground cable 35 mm2, 4 m, pressure reducer with volume and content manometer, mains cable 4 m with CEE 32-plug, fitted gas hose, operating manual. New: with basket coil adaptor as standard.

More accessories on page 50

47

M 3000. Middle and heavy weight champion. Ideal with automatic adjustment.

MIG-MAG
When you buy a Lorch system we will provide all the knowledge you need. Page 79.

48

M 3050 With or without wire feeder

M 3070 With or without wire feeder

The M for medium and heavy-duty steel work. It copes not just with thick, but thin too. As a compact system or with a separate wire feeder. An out-and-out workhorse, designed to cope with the tough all-round demands of your workshop. They all come with the same high-powered precision 4-roll feed which allows individual adjustment of pressure on the roll pairs. This is the only way to guarantee trouble-free welding of all types of wire. The housing is just as stable as the gas cylinder holder. The transformer-inductor power unit features such a finely tuned 24-step power characteristic that the ideal arc is achieved for every conceivable welding assignment. And the M series comes with a duty cycle ready to do some serious work. But the feature our development boys (and 1 girl) are most proud of has to be the totally re-engineered control system. This degree of operating convenience, functional scope and durability is an all-time first in this machine category. Take the new processor-controlled automatic adjustment for instance. The control system automatically controls the wire feed in line with the selected step. A mere touch of the correction button is enough to optimise the feed rate. The active inductor system adjusts automatically too. High-end technology from the prize-winning C-dialog takes care of minimal spatter ignition and excellent light arc characteristics. This is how easy good welding ought to be. And when it comes to functions, the M has everything covered: 2-stroke, 4-stroke, spot and interval welding. Adjustable spot and interval times. Ignition feed regulation, adjustable automatic free burning system and the knob for powerless wire insertion. The safety switch device prevents unwanted wire transport. And the stand-by function - also a standard feature - helps save energy and reduces dirt and noise. Because the fan and water cooling system are only started when they are really needed. In systems with wire feeder, you regulate the wire speed and wire feed on the spot. Which allows you to concentrate on what you are doing instead of walking backwards and forwards to the unit. In water-cooled systems, an exemplary centrifugal pump operates on demand and keeps noise to a minimum. Caution: In most cases, cheap water-cooled oscillating piston pumps are used, causing vibration in the hose set and then in the torch. And their durability leaves something to be desired. Compliance with standard EN 60974-1; CE and S marks. In short: This is everything the perfectionist needs. And anyone who owns an M 3000 qualifies as one of those.

M 3050 Welding range/ settings DC at max. current (25/40) Current at 100 % DC (40 ) Mains voltage Weldable wires steel / alum Material MIG-MAG Recommended material thickness steel / alum. Set wire Torch type (gas/water) Compact system, gas Compact system, water Feeder system, gas, 1m interm. hose set Feeder system, gas, 5m interm. hose set Feeder system, gas, 10m interm. hose set Feeder system, water, 1m interm. hose set Feeder system, water, 5m interm. hose set Feeder system, water, 10m interm. hose set Other lengths on request. 25-350A/2x12 settings 45%/30%/350 A 210 A 3x400 V 0.6-1.6 mm / 1.0-1.6 mm Steel / stainless steel / aluminium from 0.8 / from 2 mm 1.0 / 1.2 mm ML 3600 / MW 5500 203.3500.0, PG 12 203.3510.0, PG 12 203.3500.1, PG 12 203.3500.5, PG 12 203.3501.0, PG 12 203.3510.1, PG 12 203.3510.5, PG 12, 203.3511.0, PG 12

M 3070 30-400A/2x 12 settings 45%/30%/400A 240 A 3x400 V 0.6-1.6 mm / 1.0-1.6 mm Steel / stainless steel / aluminium from 0.8 / from 2 mm 1.0 / 1.2 mm - / MW 5500 203.3710.0, PG 12

203.3710.1, PG 12 203.3710.5, PG 12 203.3711.0, PG 12

Scope of delivery: System, torch with 4 m hose set, ground cable 50 mm2, 4 m long, pressure reducer, basket coil adaptor K 300, mains cable 4 m with CEE 32 plug, gas hose. With feeder systems, the connection set is ready mounted.

49

Accessories

for the

M 2000 M 3000
and

series.

Autoprotect X 10+11 Fixed protective level DIN 10. Can be converted for fixed protective level DIN 11 using the supplied spare glass. Reasonably priced, tough autoprotect helmet for MIG-MAG and electrode welding. Not suitable for TIG welding. Solar cells mean the helmet is always ready for service without the need for a battery change. Order no. 550.5311.0, (PG12)

Lorch separating spray 400 ml Forms a thin protective film in the gas nozzle to protect against sintering of hot weld splashes. Only ever spray into the nozzle from the side, never from the front, as this can clog up the gas outlet apertures on the neck of the torch. Order no. 551.9000.0 (PG2) Special pliers MIG-MAG 4 functions in a single tool. Cutting the welding wire. Cleaning splashes off the shielding gas nozzle. Pulling off the gas nozzle Releasing the contact tip. For torch ML 1500, ML 2500, Order no. 535.8225.1 (PG12) For torch ML 3600, MW 5500, Order no. 535.8226.1 (PG12)

Autoprotect Flex 9-13 With adjustable protective level from DIN 9 to 13, providing reliable protection and an optimum view for electrode, MIG-MAG and TIG welding. Convenient adjustment from outside. The light-dark switching time can be set as required, e.g. to protect eyes against weld afterglow. The detachable sensor bar allows you to eliminate the influence of the ambient light and also ensure reliable darkening in all welding positions. Solar cells, without battery. Order no. 550.5312.0, (PG12)

Autoprotect Multiflex 5-13 Highlight. Protective level DIN 5 to 13. Electrode, MIG-MAG and TIG. Sensors and daylight filters detect the arc, and the sensitivity regulator controls response in every welding situation. Wherever normal helmets give up the ghost: low welding current, fast arc changes, welding around corners with concealed arc, reflective surfaces - you can rely on the Autoprotect Multiflex to stay safely darkened. Adjustable delay time opening to prevent dazzle by weld glow. Grinding mode clear vision for grinding. Solar cells, without battery. Order no. 550.5313.0, (PG12)

MIG-MAG protective gloves Manufactured to the specifications of the Lorch specialists. Made of high-grade, durable leather. With wear-resistant seam. This is what a real welders glove should look like. Order no. 535.8210.0, (PG12)

Wire brush, 3 rows of bristles, Order no. 550.5210.0 (PG12) Wire brush, VA, 3 rows of bristles, Order no. 550.5211.0 (PG12)

Lorch coolant LCL 20 For water-cooled welding units. Frost protection to 20C. To combat cooling system corrosion and for lubrication. Combats pump seizure. 5 litres, order no. 551.9006.5 (PG 12) 25 litres, order no. 551.9006.9 (PG 12)

Ground cables With ground clamp and plug. Another case where quality counts. Steady, reliable current transmission is imperative to a neat, tidy job. Defective or worn ground cables really do have to be replaced. M 2020 to M 2090 25mm2, 4m, plug 13mm, order no.551.0120.0 M 2095 35mm2, 4m, plug 13mm, order no.551.0130.0 M 3050 and 3070 50mm2, 4m, plug 13mm, order no.551.0140.0 all (PG14)

50

Trolley for wire feeders There are plenty of us who would appreciate the convenience of not having to carry our wire feeder. We can thoroughly recommend this way of easing the work load - by letting the wheels take the strain. Chassis KE 80, Order no. 570.3024.0 (PG 12)

MIG-MAG welding wire SG2, 0.8 mm for welding unalloyed steel. Small spool D200, 5 kg, Order no. 590.0008.1 (PG12) SG2, 0.8 mm for welding unalloyed steel. Standard spool K300, 15 kg, Order no. 590.0008.6 (PG12)

Feed rolls The feed rolls for the wire feed units have to be adapted in line with the welded wire. The necessary equipment is listed in the technical data.

SG2, 1.0 mm for welding unalloyed steel. Standard spool K300, 15 kg, Order no. 590.0010.4 (PG12) SG2, 1.2 mm for welding unalloyed steel. Standard spool K300, 15 kg, Order no. 590.0012.4 (PG12)

Feed rolls M 2020 to M 2080 For steel/stainless steel wires 0.6 / 0.8 mm Order no. 620.8700.0 (PG12) For steel/stainless steel wires 0.8 / 1.0 mm Order no. 620.8701.0 (PG12) For steel/stainless steel wires 1.0 / 1.2 mm Order no. 620.8710.0 (PG12) For aluminium wires 1.0 /1.2 mm Order no. 620.8710.1 (PG12)

AlMg5, 1.0 mm for welding aluminium. Small spool D200, 2.0 kg, Order no. 590.0410.0 (PG12) AlMg5, 1.2 mm for welding aluminium. Small spool D200, 2.0 kg, Order no. 590.0412.0 (PG12)

Feed rolls for M 2090, M 2095, M 3050, M 3070 Where 4-roll drive is used for these units, 2 feed rolls are always required. Please remember when ordering. For steel/stainless steel wires 0.6 / 0.8 mm Order no. 620.8940.0 (PG14) For steel/stainless steel wires 0.8 / 1.0 mm Order no. 620.8709.0 (PG14) For steel/stainless steel wires 1.0 / 1.2 mm Order no. 620.8941.0 (PG14) For steel/stainless steel wires 1.2 / 1.6 mm Order no. 620.8942.0 (PG14) For aluminium wires 1.0 /1.2 mm Order no. 620.8953.0 (PG14) For aluminium wires 1.2 /1.6 mm Order no. 620.8954.0 (PG14)

1.4316, 0.8 mm for welding stainless steel (V2A). Small spool D200, 5.0 kg, Order no. 590.0208.1 (PG12)

Adaptor for small spools This adaptor is required when working with plastic spools with a 200 mm dia. It is used as a spacer and guarantees reliable wire feed. Order no. 620.9650.0 (PG 12) Adaptor for basket coils K300 basket coil adaptor K300 is required for placing basket coils into the wire roll fixture. This is included in the scope of delivery of the M series. To order spares: Order no. 551.9020.0 (PG12)

51

Accessories

for the

M 2000 M 3000
and

series.

Original equipment kit for torch ML 1500, 3 m Kit including the most important torch wearing parts at an affordable all-in price. Contains: 1 tapered gas nozzle, 1 spot gas welding nozzle, 5 contact tips 0.8 mm, 1 liner blue 0.6-0.9 mm, 3 retaining springs, 1 Lorch separating spray 400 ml. Order no. 551.1021.0 (PG2)

Torch original equipment kit in a case Each case containing the different accessory kits shown on the left - but packaged safely and neatly in a sturdy plastic case with handy compartments.

Order no. 551.0490.1 (PG12), for ML 1500 Order no. 551.0490.2 (PG12), for ML 2500 Order no. 551.0490.4 (PG12), for ML 3600 Order no. 551.0491.0 (PG12), for MW 5500

Original equipment kit for torch ML 2500, 3 m Kit including the most important torch wearing parts at an affordable all-in price. Contains: 1 tapered gas nozzle, 1 spot gas welding nozzle, 5 contact tips 1.0 mm, 1 liner red 1.0-1.2 mm, 3 retaining springs, 1 contact tip holder, 1 Lorch separating spray 400 ml. Order no. 551.1023.0 (PG2)

Set of torch wearing parts for ML 1500 Case containing the following main wearing parts . 3 tapered gas nozzles, 10 contact tips 0.8 mm, 10 retaining springs. Order no. 551.1508.0 (PG12)

Original equipment kit for torch ML 3600, 4 m Kit including the most important torch wearing parts at an affordable all-in price. Contains: 1 tapered gas nozzle, 1 cylindrical gas nozzle, 5 contact tips 1.0 mm , 1 contact tip holder, 1 gas diffuser, 1 liner red 1.0-1.2 mm, 1 Lorch separating spray 400 ml. Order no. 551.1036.0 (PG2)

Set of torch wearing parts for ML 2500 Case containing the following main wearing parts : 3 tapered gas nozzles, 10 contact tips 1.0 mm, 10 retaining springs. Order no. 551.2510.0 (PG12)

Set of torch wearing parts for ML 3600 Case containing the following main wearing parts : 3 tapered gas nozzles, 10 contact tips 1.0 mm, 1 contact tip holder, 1 gas diffuser. Order no. 551.2136.0 (PG12)

Original equipment kit for torch MW 5500, 4 m Kit including the most important torch wearing parts at an affordable all-in price. Contains: 3 tapered gas nozzles, 5 contact tips 1.2 mm, 1 contact tip holder, 1 gas diffuser, 1 liner 1.0-1.2 mm, 1 Lorch separating spray 400 ml. Order no. 551.1055.0 (PG02)

Set of torch wearing parts for MW 5500 Case containing the following main wearing parts 3 tapered gas nozzles 10 contact tips 1.0 mm 10 contact tips 1.2 mm 1 contact tip holder 1 gas diffuser. Order no. 551.2155.0 (PG12)

52

Only original complete burners from Lorch

Ergonomics, a highly flexible hose set, wear-proof torch neck and optimum current transmission all interact in these torches to ensure optimum welding characteristics and a service life that pays dividends. Torch ML 1500 for the M 2020, M 2040, M 2060 ML 1500, 3 m long, order no. 503.1500.3 (PG2) ML 1500, 4 m long, order no. 503.1500.4 (PG2) Conversion kit aluminium How to convert your torch for welding aluminium wire 1.0 / 1.2 mm. Kit contains: Special combination teflon liner with flange-mounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. The set can be used for torches up to 4 m in length. To prevent wire damage, we recommend using 1.2 mm wire with a 3 m torch. Please order the matching contact tips and aluminium feed rolls separately. Order no. 551.2014.0 (PG2)

Torch ML 2500 for the M 2080, M 2090 ML 2500, 3 m long, order no. 503.2500.3 (PG2) ML 2500, 4 m long, order no. 503.2500.4 (PG2) ML 2500, 5 m long, order no. 503.2500.5 (PG2)

Conversion kit stainless steel, 0.6/0.9 mm How to convert your torch for welding stainless steel wire. Kit contains: Special combination carbon-teflon liner with flangemounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. The set can be used for torches up to 5 m in length. Please order the matching contact tips and aluminium feed rolls separately. Order no. 551.2015.0 (PG2)

Torch ML 3600 for the M 2095, M 3050, gas-cooled ML 3600, 3 m long, order no. 503.3600.3 (PG2) ML 3600, 4 m long, order no. 503.3600.4 (PG2) ML 3600, 5 m long, order no. 503.3600.5 (PG2)

Torch MW 5500 for the M 3050, M 3070, water-cooled MW 5500, 3 m long, order no. 503.5500.3 (PG2) MW 5500, 4 m long, order no. 503.5500.4 (PG2) MW 5500, 5 m long, order no. 503.5500.5 (PG2)

Conversion kit stainless steel, 1.0/1.2 mm How to convert your torch for welding stainless steel wire 1.0 / 1.2 mm Kit contains: Special combination PA liner with flange-mounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. The set can be used for torches up to 5 m in length. Please order the matching contact tips and aluminium feed rolls separately. Order no. 551.2015.2 (PG2)

53

Accessories M 2000 M 3000

Spare torch necks to fit: ML 1500 also f. MS15, order no.535.8400.1 (PG02) ML 2500 also f. MS25, order no.535.8400.2 (PG02) ML 3600 also f. ML36, order no.535.8400.4 (PG02) MW 5500 order no.535.8400.5 (PG02)

Contact tips for torch, ML 1500, (PG02) Pack Order no. Design 0.6 mm M6 5 535.8101.1 0.8 mm M6 5 535.8101.2 1.0 mm M6 5 535.8101.3 For aluminium wire 1.0 mm M6 5 535.8101.5 1.2 mm M6 5 535.8101.6 Contact tips torch, ML 2400, 2500, 3600, (PG02) 0.6 mm M6 5 535.8106.1 535.8106.2 0.8 mm M6 5 1.0 mm M6 5 535.8106.3 1.2 mm M6 5 535.8106.4 For aluminium wire 1.0 mm M6 5 535.8106.5 1.2 mm M6 5 535.8106.6 Contact tips for torch, MW 5500, (PG02) 0.8 mm M8 10 535.8108. 1.0 mm M8 10 535.8108.3 1.2 mm M8 10 535.8108.4 For aluminium wire 535.8108.5 10 1.0 mm M8 1.2 mm M8 10 535.8108.6 For gas nozzles, (PG02) For ML 1500 10 For ML 2500 10

Liners for ML 1500, ML 2500, ML 3600 Also to fit MS 15, MS 25, ML 36 Liner for wire 0.6 - 0.9 mm, colour code blue For 3 m torch, (PG02), order no. 535.8300.1 For 4 m torch, (PG02), order no. 535.8300.2 Liner for wire 1.0 - 1.2 mm, colour code red For 3 m torch, (PG02), order no. 535.8300.3 For 4 m torch, (PG02), order no. 535.8300.4 For 5 m torch, (PG02), order no. 535.8300.5

535.8100.9 535.8105.9

Contact tip holders, (PG02) For ML 2500 2 For ML 3600 2 For MW 5500 2 Gas diffuser, (PG02) For ML 3600 For MW 5500

535.8106.9 535.8107.2 535.8108.9

Liners for MW 5500, Wire 1.0 - 1.2 mm For 3 m torch, (PG02), order no. 535.8301.0 For 4 m torch, (PG02), order no. 535.8302.0 For 5 m torch, (PG02), order no. 535.8303.0

2 2

535.8107.3 535.8108.8

Gas nozzles, plug-in, for torch ML 1500, (PG02) Tapered gas nozzle 3 535.8100.1 Cylindrical gas nozzle 3 535.8100.2 3 535.8100.3 Spot gas nozzle Gas nozzles, plug-in, for torch ML 2500, (PG02) Tapered gas nozzle 3 535.8105.1 Cylindrical gas nozzle 3 535.8105.2 Spot gas nozzle 3 535.8105.3 Gas nozzles, plug-in, for torch ML 3600, (PG02) Tapered gas nozzle 3 535.8107.0 Cylindrical gas nozzle 3 535.8107.1 Gas nozzles, plug-in, for torch MW 5500, (PG02) Tapered gas nozzle 2 535.8109.0 Cylindrical gas nozzle 2 535.8109.1

54

To date it all revolved around MIG-MAG. Corrosion protection and higher-strength steel sheet are ringing the changes. What next?
MIG-brazing

MIG-MAG

55

The Lorch M 3030 automotive. MIG brazing and MIG-MAG in one. The answer to the stream of new materials and regulations.
Whoever processes high quality steel today buys the M 3030 automotive. The future demands it. A combined MIG brazing and MIG-MAG welding unit is the logical solution. Up until now it was all simple sheet. Little thought was given to the quality of properties required from high quality thin sheet welding or the newly introduced MIG brazing (MSG brazing). Customer demands are changing to being more strict and specific. For example: incorrect welding or brazing on/at a vehicle may result in a delayed activation of the airbag, sheet structure or corrosion resistance may be destroyed. Already today, MSG brazing is mandatory in every Opel workshop. Tailored blanks, modern high strength steels and the benefits of MIG brazing are making your welding machine obsolete. High strength steels are all set to take over in the future. Times have changed. MIG brazing units are already an established feature in wide-ranging fields such as the automotive industry, steel furniture manufacture, container construction and many more. MIG brazing is a hard soldering technique in which the required process energy is generated by an electrical arc. A MIG-MAG welder will easily get to grips with it. Instead of steel wire, the arc melts a solder wire. The process temperature is well below that needed for MIG-MAG. Sheet is not melted, the solder creates a firm joint that is gentle on the material. The benefits of MIG brazing include minimal material distortion and low heat generation. Ideal for thin sheet. No change occurs in the base material. Strength is uncompromised. Welding state-of-the-art materials. No corrosion of the brazing seam. In coated sheet, the zinc coating remains undamaged even in the brazing seam zone. Corrosion resistance is guaranteed without the need for any subsequent treatment. Optimum gap bridgability. Minimal spatter and a soft brazing seam reduce the need for reworking. So if thin sheet is an issue for you, the M 3030 automotive awaits. As far as we are concerned, its cost-to-performance ratio among available systems is second to none. Method MIG brazing/MIG-MAG welding

Brazing-/ Welding range 30 260 A / 11.4 27 V 41 Digastep performance steps Settings Duty cycle at max. current (40) 35 % at 260 A Welding current at 60 % DC (40) 200 A Welding current at 100 % DC (40) 160 A Weldable wires steel 0.6 - 1.2 mm Weldable wires aluminium 1.0 - 1.2 mm Brazable wires 0.8 1.0 mm Mains voltage 3 x 400 V Material Steel/stainless steel/aluminium Material thickness steel 0.8 10 mm Material thickn. alum. (welding only) 2 - 6 mm Set wire diameter 0.8 mm / 1.0 mm brazing wire Order number (PG12) 203.3300.0 Scope of delivery: Unit with remote-control torch ML 2400 PowerMaster, 3 m; MIG brazing torch set with combination carbon-teflon liner; ground cable 35 mm long; pressure reducer with volume and contents manometer, adaptor for basket coils K300; mains cable 4 m with CEE 16-plug, fitted gas hose, operating manual.

56

Totally digital the whole process. Arc control, ignition control, gas management system, wire burn-back without electrode sticking, wire speed control. Built-in diagnostics. Tacking, continuous, spot or interval.

No more experimenting with step switches. The welding unit gives the correct settings. Fully automatic correct welding and brazing. Digastep electronics control the process. Perfectly adjusted power stages result in a new quality of work. You dont need to pay for a pulse-arc unit in order to experience simple welding. Innovation award 2001 of the German Federal Ministry of Research and Development.

Just 4 settings for perfect welding and brazing. Material wire diameter gas thickness of material. Ready. Everything else is adjusted by the M3030 Automotive. The best parameters are applied. Stored in a data base with the knowledge of the best welders. By setting to the expert mode, specialists can always intervene in the system. But actually there is no reason why they should.

The new Power-Master-Torch. Integrated remote control and display, wire speed control, power and tiptronic can all be controlled at the torch. This would normally be an expensive extra feature.

Job memory. The Tiptronic. 100 work values can be saved and activated with a switch at the torch. Complete sets of procedures. Manufacturers guidelines. All stored time-saving.

Digital display for voltage and current. Voltage and current values will be prescribed by future repair guidelines. All integrated ready for action.

Active Induction System (AIS). Ignition without spatter, brazing and welding with a constant arc even in the lower power range. No arc breaks or spatter. AIS automatically controls the induction coil under all conditions. This is our secret. If compared to a car, it would be the perfect adjustment of the suspension in a fraction of a second.

Undisturbed wire feed due to precise 4-roll drive system.

So inexpensive. How is that possible? Just 2,930.We dont believe that your job is to build a steel bridge across the River Nile, so the M 3030 is not equipped to perform such a task. Neither do we believe that you require a new pulse-arc unit for your new tasks. In our opinion, and from our experience, you need the M 3030 Automotive. It would be easy to recommend one of our more expensive welding machines. But we dont, it is a matter of trust. Everything complete. Unit, powerMaster torch with 3 metre hose set, pressure reducer, ground cable.

57

Accessories M 3030 automotive

Autoprotect X 10+11, protection level DIN 10. Converts to DIN 11. MIG-MAG /Electrode welding. Order no. 550.5311.0 (PG12) Autoprotect Flex 9-13 Protection level DIN 9 up to 13. Electrode/ MIG-MAG/TIG. Dark/light switching. Sensor web. Order no. 550.5312.0 (PG12) Autoprotect Multiflex 5-13 Protection level DIN 5 up to 13. Electrode/ MIG-MAG/TIG. Daylight filter, sensitivity regulator. Goes on where normal helmets give up the ghost. Order no. 550.5313.0 (PG12) Feed rolls The feed rolls used in the wire feed unit have to be adapted in line with the wire you are welding. The feed rolls supplied for the M 3030 allow two different diameters to be processed. Fitted as standard with 0.8/1.0 mm aluminium feed rolls for processing brazing wires. The dual drive system always requires 2 feed rolls. Feed roll for steel- and stainless steel wires (MIG-MAG) Wire diameter 0.6/0.8 mm, order no. 620.8940.0 (PG14) Wire diameter 0.8/1.0 mm, order no. 620.8709.0 (PG14) Wire diameter 1.0/1.2 mm, order no. 620.8941.0 (PG14) Feed roll for aluminium and brazing wires Wire diameter 0.8/1.0 mm, order no. 620.8708.0 (PG14) Wire diameter 1.0/1.2 mm, order no. 620.8953.0 (PG14)

Lorch separating spray 400 ml Forms a thin protective film in the gas nozzle to protect against sintering of hot weld splashes. Order no. 551.9000.0 (PG2)

CuSi3 wire for galvanised sheet 0.8 mm, small spool D200, 5 kg, order no. 590.1008.1 (PG 12) 0.8 mm, basket coil K300, 15 kg, order no. 590.1008.3 (PG 12) 1.0 mm, small spool D200, 5 kg, order no. 590.1010.1 (PG12) 1.0 mm, basket coil K300, 15 kg, order no. 590.1010.3 (PG12) CuAl8 wire for stainless steel 0.8 mm, small spool D200, 5 kg, order no. 590.1108.1 (PG 12) 0.8 mm, basket coil K300, 15 kg, Best. Nr 590.1108.3 (PG 12) 1.0 mm, small spool D200, 5 kg, order no. 590.1110.1 (PG12) 1.0 mm, basket coil K300, 15 kg, order no. 590.1110.3 (PG12)

Special pliers MIG-MAG 4 functions. Cutting the welding wire. Cleaning the shielding gas nozzle. Pulling off the gas nozzle. Releasing the contact tip. Order no. 551.9070.0 (PG12)

MIG-MAG protective gloves Made of high-grade, durable leather. With wear-resistant seam. What a real welders glove should look like. Order no. 535.8210.0 (PG12)

Wire brush, 3 rows of bristles, Order no. 550.5210.0 (PG12) Wire brush VA, 3 rows of bristles, Order no. 550.5211.0 (PG12)

Adaptor for small spools This adaptor is required when 200 mm diameter spools are used. It serves as a spacer and guarantees reliable wire insertion. Order no. 620.9650.0 (PG 12)

Ground cables with ground clamp and plug Steady, reliable current transmission is imperative to a neat tidy job. Defective or worn ground cables really do have to be replaced. 35mm2, 4m, plug 13mm, Order no. 551.0130.0

Adaptor for basket coils K 300 The basket coil adaptor K 300 is required when using basket coils in the wire roll holder Order no. 551.9020.0 (PG12)

58

PowerMaster torch. Regulate power and speed by remote control in the torch itself.

MIG brazing torch set, 0.6-1.0 mm, also for stainless steel. Contents: Special combination carbon-teflon liner with flange-mounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. The set can be used for torches up to 5 m in length. Please order the matching contact tips and aluminium feed rolls separately. Order no. 551.2015.0 (PG2) Spare torch necks to fit: ML 1500 PowerMaster, order no.535.8400.1 (PG02) ML 2400 PowerMaster, order no.535.8400.3 (PG02)

Torch ML 1500 PowerMaster for M 3030 automotive Specifically for car body work. Compact, handy design. Max. current load 200 A. When used for MIG brazing, brazing torch set order no. 551.2015.0 is additionally required. For higher outputs, use torch ML 2400 PM. ML 1500 PM, 3 m, order no. 503.1501.3 (PG02)

Liners for ML 1500 PM, ML 2400 PM Liner for steel wire 0.6 - 0.9 mm, colour code blue For 3 m torch, (PG02), order no. 535.8300.1 For 4 m torch, (PG02), order no. 535.8300.2 Liner for steel wire 1.0 - 1.2 mm, colour code red For 3 m torch, (PG02), order no. 535.8300.3 For 4 m torch, (PG02), order no. 535.8300.4 For 5 m torch, (PG02), order no. 535.8300.5

Torch ML 2400 PowerMaster for M 3030 automotive Universal torch to cover the entire performance range. When used for MIG brazing, brazing torch set order no. 551.2015.0 is additionally required. ML 2400 PM, 3 m, order no. 503.2401.3 (PG02) ML 2400 PM, 4 m, order no. 503.2401.4 (PG02) ML 2400 PM, 5 m, order no. 503.2401.5 (PG02)

Conversion kit aluminium 1.0 - 1.2 mm Contents: Special combination teflon liner with flangemounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. The set can be used for torches up to 4 m in length. To prevent wire damage, we recommend using 1.2 mm wire with a 3 m torch. Please order the matching contact tips and aluminium feed rolls separately. Order no. 551.2014.0 (PG2)

Contact tips for torch, ML 1500 PM, PG2 Design Pack Order no. 0.6 mm M6 5 535.8101.1 0.8 mm M6 5 535.8101.2 1.0 mm M6 5 535.8101.3 For aluminium wire 1.0 mm M6 5 535.8101.5 1.2 mm M6 5 535.8101.6 Contact tips for torch, ML 2400 PM, PG2 0.6 mm M6 5 535.8106.1 0.8 mm M6 5 535.8106.2 1.0 mm M6 5 535.8106.3 1.2 mm M6 5 535.8106.4 For aluminium wire 1.0 mm M6 5 535.8106.5 535.8106.6 5 1.2 mm M6 Holding springs for gas nozzles, PG2 For ML 1500 PM 10 535.8100.9 Contact tip holders, PG2 For ML 2400 PM 2 535.8120.4 Gas diffuser, PG2 For ML 2400 PM 2 535.8120.3 Gas nozzles, plug-in, for torch ML 1500 PM, PG2 Tapered gas nozzle 3 535.8100.1 Cylindrical gas nozzle 3 535.8100.2 Spot gas nozzle 3 535.8100.3 Gas nozzles, plug-in, for torch ML 2400 PM, PG2 Tapered gas nozzle 3 535.8120.1 Cylindrical gas nozzle 3 535.8120.2

59

A promi s is a prom
The rating plate. The bearer of truth. Or the last chance to bend the truth a little ??
You would imagine that this type of rating plate has to present the bare facts. The truth. We believe that the truth is what you get from Auenwald. Because we pledge and guarantee not to deceive anyone. We know manufacturers who do. Even on the rating plate. So we send our development engineers for 34 days a year to sit on committees and advisory panels at leading electrical engineering industry associations such as the DKE and the ZVEI, as well as the DIN standardisation agency, to help safeguard your interests. The S mark Only units complying with regulations for welding in environments subject to high levels of electrical risk may bear this mark. High levels of electrical risk occur, for instance, when the welder is forced to make contact with electrically live parts. Workplaces in which the clearance from surrounding electrically conductive parts is less than two metres also qualify as at high electrical risk. The same applies to wet or damp workplaces in which the electrical resistance of work clothing or human skin can be reduced. Watch out! A high current rating is good. But is the relevant standardised working voltage right? It is only the current and voltage together which determine the necessary melting rate. Dont be fooled by illusory current values.

The protection class IP Protection classes according to type of housing (IP Code) are regulated by European standard EN 60529. Welding current sources must comply with protection class IP 21S as a minimum requirement. Always remember: Welding current sources which have to be used outdoors must comply with at least protection class IP 23. Anyone offering assembly units protected to IP 21 should be treated with suspicion.

60

se made mise kept

The standards EN 60974-1 for Europe, VDE 0544 Part 1 for Germany. They contain the same thing, and are applicable for all welding current sources used for arc welding. Duty cycle, mechanical and electrical safety, type and piece testing etc. are all laid down in these standards. Why doesnt everyone stick to them? The duty cycle This is real test of honesty. In a MIG-MAG welding unit with a 60% duty cycle at 220 A this means: Welding current 220 A. The standardised welding voltage is 25V. The ambient temperature is set at 400C. The measurement period is always 10 minutes. 60% means 6 minutes of welding, 4 minutes break. Hours, days, weeks. So be wary of statements like ...200 A at 250C ambient temperature or ...60% duty cycle at intervals of 5 minutes, which are clearly in contravention of the standard.

Anyone who cheats is disqualified. We guarantee the accuracy of the values we specify. If you ever find your unit fails to live up to this claim, return it to us. We will give you your money back. No matter how old it is.
Lorch, Auenwald, 2006 61

There are no that give mor they

The inverter. Where honesty is the best policy. A new type of welder the inverter has arisen from of the development of power electronics. The mains current is firstly converted into a direct current by diodes and then electronically "chopped" before being "smoothed". This is the only way to achieve a high transmission frequency. The consequence: a smaller and lighter transformer. Sounds simple, but it involves very complicated electronics. The duty cycle (DC). No unnecessary compulsory breaks please. Mains voltage cannot be converted into welding voltage without losses. These are related to the internal resistance of the conductor. In Auenwald we use copper and nothing else for this construction. Many other use aluminium Technically speaking, inverter units do not for cost reasons. The consequence is that the have a lot in common with welding transform- unit heats up faster. And what happens? Your ers. They are complicated devices with a low machine has to cool down and switches itself weight and compact design, but with excellent off. The more often this happens, the worse it welding properties. This technology is very is for the service life of the machine. expensive and entails a great deal of develop- The relationship between the welding time ment work. Something that many manufactur- and cooling phase is called the duty cycle. ers dread and therefore buy in from "elseThe standard EN 60974-1 is applicable when it where" abroad. After assembly they stick their comes to determining the duty cycle of profesown trademark, and in some cases "Made in sional units. (The standard EN 50060 applies Germany", on the device and Bob's your for devices for limited use and hobby purposuncle. Good ? Without their own experience, es.) The duty cycle is determined within a at the mercy of quality and know-how from cycle period of 10 minutes (100%) A duty cycle "elsewhere". Let's assume you need a spare of 60% thus means that the welding time is 6 part after a few years. Just remember, we minutes (60%) and the cooling time 4 minutes build our own inverters and know why. (40%).

A question of trust.

62

not many things ore back than receive.

Standard data can be used to compare various welding accessories. The duty cycle is determined at a certain ambient temperature. Until recently this was 25C, i.e. a temperature corresponding to average use in central Europe. This has now been raised to 40C. In some cases, during the transitional phase, this led to inaccurate comparisons. Which is why we specify values at both 25C and 40C for most of our welding accessories. You have the right information, and can compare for yourself. In principle, the higher the duty cycle, the fewer the unavoidable breaks. Amperes! Doesnt mean a lot on its own. The engine of a VW Golf can be rebored so that it shoots along at 250 kp/h. The question is, how would it handle? Hopefully it would still run straight ahead. A similar situation applies for welding devices when it comes to amperes (horse power). These tell you how much current is flowing in the arc. That's all. But welding, properties, ignition, inductor combination, no-load voltage, working voltage, optimum penetration and much more also have to be taken into account. Mains fuses. Some have their limitations. Let's assume you want to weld, working with a 230 V (lighting) power supply. But the mains fuse keeps blowing. Tiresome. Or you are working with a long extension lead and you simply don't have enough power for welding! We would like to explain briefly what exactly happens here. The energy needed in the arc or melt has to come directly from the mains supply. We have developed SPM (SinePowerManagement) specially for this. Our rivals have already read the most important features in our patent. However we are still keeping some "industrial secrets". These are securely under lock and key in our safe in Auenwald.

Only when all these aspects are optimised do you end up with a useful unit. This is expressed in what are commonly called welding properties. These are responsible for the welding speed, seam appearance and volume of spatter. However, you can still see people spending hours grinding off weld spatter. Over the years you lose more than just good money. But it's a well known fact that performance has its price though with us this does not have to be unnecessarily high.

63

The Lorch inverter plasma cutting units. Z 70 and Z 110. 4 times hotter than the sun itself. Incredible speed, durability, mobility.
Fact is: Units in this power class usually weigh around 100kg. These get either weight lifted in the workshop like stone age monoliths or transported on site with a crane, if there happens to be one. This is history. Two newly developed plasma-cutting-inverter are playing this easy (to-carry) part in the market now. They cut bolt upright, circular, around angles, forward, to the left and to the right, all electrical conductive metals. Steel, stainless steel, aluminium, brass, copper. Sheet steel or pipes/tubes, container or steel beams: coated or laminated surfaces, even piled up sheets: usable with steel, container and construction work, air condition technology, on site. For cutting, preparation of welding seams, joint planing, hole pricking. And should you ever forget the combination of your safe, with a Lorch inverter plasma cutting unit you will be able to get your hands on your millions again in just seconds. Due to the infinitely variable adjustment of cutting and power intensity, both thick and thin materials can be accomplished with a neat cutting edge. Microprocessor controlled plasma logic enables the cutting of hole sheets and grates without interruption. Plasma-cutting is quite simple: you need the plasma cutting unit and compressed air. The produced plasma arc develops a temperature of up to 24.000C. Four times more than the surface of the sun. The aerate pushes the liquid material out of the joint. The concentrated energy input enables highest cutting speeds. The fast energy input means: minor heat, minor distortion and exact cutting edges even on thin metal sheets. A plasma cutting unit which generates its current using an inverter offers obvious benefits over a unit equipped with a conventional transformer. Substantially lower energy consumption for one. And we all know the cost of electricity. Soft-start ignition also places minimum stress on the cutting electrodes. A far longer service life and clearly improved cutting quality. Benefits you can start enjoying as soon as you like.

Plasma cutting

5064

65 51

Inverter plasma cutting unit Z 70, including torch 30 kg high-end durable technology, 70 Ampere

Inverter plasma cutting unit Z 110, including torch 31 kg go down to 42 mm depth, 110 Ampere

The technology: Primary Inverter-Powerpack. Minimal energy consumption. Controlled pilot arc for reliable ignition. Infinitely variable adjustment offers a cutting result ideally adapted to the material thickness, resulting in neat, precise cutting edges and optimised work speeds. Microprocessor controlled logic: high-frequency ignition and pilot arc for no-contact ignition. Soft switching for minimum strain on nozzles, digital display of cutting current and compressed air. Air flow control, air test function for convenient pressure adjustment. Automatic cool air post-flow noticeably increases the durability of the wearing parts. Digital security switching, display for all important status information. On-demand cooling with stand-by-switching: less power use, noise and contamination. Combined plasma torch. Cutting with spacer: precise and exact cuts, long service life, high cutting speed. Contact cutting with touch-down torch when working under cramped conditions. The torch is easily exchangeable due to the central mounting system. Interface for automatic solutions

Method Setting range cutting current inf. variable Cutting current at 100% DC (40C) Duty cycle at max. current (40C) Mains voltage Mains fusing Measurements appr. (LxWxH) Weight Air consumption Air pressure Max. separating/quality cut with steel Max. separating/quality cut with aluminium Max. separating/quality cut with stainless steel

Z 70 Plasma cutting 22-70 A 50 A 60 % (70 A) 400 V 16 A tr. 650x260x470 mm 30 kg 170 l/min 5.5-7 bar 22 / 17 mm 17 / 12 mm 18 / 14 mm Order no. 321.0007.0 (PG 12)

Z 110 Plasma cutting 25-110 A 60 A 35 % (110 A) 400 V 32 A tr. 650x260x470 mm 31.5 kg 200 l/min 5.5-7 bar 37 / 32 mm 27 / 22 mm 30 / 24 mm Order no. 321.0011.0 (PG 12)

Scope of delivery: Unit complete with 6m torch type LCT 80 for model Z 70 or type LCT 150 for model Z 110. Ground cable 25mm; air pressure nozzle fitting, pressure reducer with filter for compressed air, mains cable 4 m with CEE 16 plug at model Z 70 or CEE 32 plug at model Z 110. Operating manual. Incl. wearing part set for the cutting torch.

Circle cutting attachment 2 pivot rods 250 mm + 400 mm, 3 pivot points, torch trolley. For torch LCT 80 Order no. 535.4015.0 (PG 14) For torch LCT 150 Order no. 560.0045.0 (PG 14)

Workshop trolley Straighten up out of that crouch position. This is the ergonomically optimum position for the equipment. For fast, pleasant working. The base makes a perfect resting surface. Order no. 570.3001.0 (PG 12)

66

Torches and wearing parts for the Z.

Complete torch LCT 80 Plasma cutting torch with central connection and 6 m long hose set. With original equipment set: 1 cutting electrode, 2 cutting nozzles, 5 spacer springs, 1 flowmeter. Order no. 511.9507.0, PG 2

Complete torch LCT 150 Plasma cutting torch with central connection and 6 m long hose set. With original equipment set: 1 cutting electrode, 2 cutting nozzles, 5 spacer springs, 1 flowmeter. Order no. 511.9515.0, PG 2

10 15 25 30 45 50 10 20 30 40 50 30 45 55 30 40 50 100 110 120 58 25 20

130

60

70

80

90

130

60

70

80

90

140

150

Plasma cutting torch LCT 80, PG 2 Pos. Order no. Pack Name 10* 535.8503.0 2 Diffusor Cutting electrode, short 5 20* 535.8503.1 30* 535.8503.2 2 Gas diffuser 40 535.8503.3 5 Cutting nozzle 1.0 < 50A 40 535.8503.4 5 Cutting nozzle 1.1 40-60A 40* 535.8503.5 5 Cutting nozzle 1.2 50-80A 50* 535.8503.6 1 Protective cap18.70 60* 535.8503.7 10 Spacer spring standard cut 70 535.8503.8 1 Spacer nozzle 4-point seating, vertical cut/template 80 535.8503.9 1 Spacer nozzle 2-point seating, oblique cut/mitre 1 Torch trolley (PG14) 535.8504.0 90 Long design and for contact cutting 15 535.8504.2 2 Diffusor, long 25 535.8504.3 5 Cutting electrode, long 5 Cutting nozzle, long 1.2 535.8504.4 45 130 535.8504.5 2 Contact nozzle, long * = Original equipment Cutting quality and safety during cutting depend on the quality of the torch. Experimentation is not an option here.

Plasma cutting torch LCT 150, PG 2 Pos. Order no. Pack Name 10* 535.8500.0 2 Diffusor 20* 535.8500.1 5 Cutting electrode short 30* 535.8500.2 2 Gas diffuser 40 535.8500.3 5 Cutting nozzle 1.4 50-80A 40* 535.8500.4 5 Cutting nozzle 1.6, 70-120A 40 535.8500.5 5 Cutting nozzle 1.8, 100-150A 40 535.8500.6 5 Cutting nozzle 3.0 gouging 50* 535.8500.7 1 Protective cap cylindrical 60* 535.8500.8 10 Spacer spring standard cut cut/template 70 535.8500.9 1 Spacer nozzle 4-point seating, vertical oblique/mitred 80 535.8501.0 1 Spacer nozzle 2-point seating, cut 90 535.8501.1 1 Torch trolley (PG14) 58 535.8501.2 1 Tapered prot. cap Pos. 140+150 100 535.8501.3 1 Adaptor ring 110 535.8501.4 5 Cylindrical nozzle guard ring 120 535.8501.5 5 Tapered nozzle guard ring cut, cylindrical, 140 535.8501.6 1 Spacer nozzle Contact and mitre vertical Contact cut round, 150 535.8501.7 1 Spacer nozzle vertical and mitre Long design and for contact cutting 25 535.8502.0 5 Cutting electrode, long 45 535.8502.1 5 Cutting nozzle, long 1.4 50-80A 45 535.8502.2 5 Cutting nozzle, long 1.7 70-120A 45 535.8502.3 5 Cutting nozzle, long 1.9 100-150A 55 535.8502.4 1 Protective cap 130 535.8502.5 2 Contact nozzle, long 67

Lorch AUTOprotects
What the eye doesnt see, the hand cannot reach.

We dont manufacture this helmet ourselves and it was not born in Auenwald. It doesnt even come from Germany, because we could not find anything like it at home. Nevertheless it convinced us and we can thoroughly recommend it in the interests of your work and your health. We believe it offers the best view for positioning the torch welding rod. Its immediate darkening on ignition means an almost linear conversion at the speed of light. This automatic protection against temporary blinding is also a perfect, sturdy face protection against radiation, sparks and spatters. Energy is supplied by solar power. Always ready to use. Goodbye batteries. The appealing design of the helmet does nothing to compromise optimum ear protection against UV radiation. A headband design with facility for a wide range of different adjustments helps optimise wearing comfort .

68

Autoprotect X 10+11 Fixed protective level DIN 10. Can be converted for fixed protective level DIN 11 using the supplied spare lens. Reasonably priced, tough autoprotect helmet for MIGMAG and electrode welding. Not suitable for TIG welding. Solar cells mean the helmet is always ready for service without the need for a battery change. Order no. 550.5311.0 (PG12)

Autoprotect Flex 9-13 With adjustable protective level from DIN 9 to 13, providing reliable protection and an optimum view for electrode, MIG-MAG and TIG welding. Convenient adjustment from outside. The light-dark switching time can be set as required, e.g. to protect eyes against weld afterglow. The detachable sensor bar allows you to eliminate the influence of the ambient light and also ensure reliable darkening in all welding positions. Solar cells, without battery. Order no. 550.5312.0 (PG12)

Autoprotect Multiflex 5-13 Highlight with adjustable protective level DIN 5 to 13. Electrode, MIG-MAG and TIG. Sensors and daylight filters detect the arc, and the sensitivity regulator controls response in every welding situation. Wherever normal helmets give up the ghost - low welding current, fast arc changes, welding around corners with concealed arc, reflective surfaces - you can rely on the Autoprotect Multiflex to stay safely darkened. Adjustable delay time opening to prevent dazzle by weld glow. Grinding mode clear vision for grinding. Solar cells, without battery. Order no. 550.5313.0 (PG12)

Torch and welding rod, ideally positioned.

Ignition: Instantaeneous darkening, light/dark switching time 0.001 of a second.

Order no. 550.5320.0 550.5320.2 550.5320.4 535.8700.0 535.8700.2 535.8700.4 535.8700.6 535.8700.8 535.8701.0 535.8701.2 535.8701.4 535.8701.6 535.8701.7 535.8701.8 535.8701.9

Name (helmets and parts PG 12) Helmet shell cmpl. with headband X10+11 Helmet shell cmpl. with headband Flex 9-13 Helmet shell cmpl. with headband Multiflex 5-13 Spare lenses, scratchproof X10+11 / pack of 10 Spare lenses, scratchproof Flex 9-13 / pack of 5 Spare lenses, scratchproof Multiflex / pack of 5 Spare lenses, internal / pack of 5 (all types) Headband cmpl. including sweatband Spare cartridge for X 10+11 Spare cartridge for Flex 9-13 Spare cartridge for Multiflex 5-13 Leather head and neck protector (all types) Leather chest protector (all types) Sweat band cotton / pack of 2 Helmet adaptor for work safety helmets (all types)

69

Welders ac
Welding accessories Professional welding equipment with highly flexible welding cable, electrode holder and ground clamp Protective shield EN 166 Welding glasses DIN 4646/4647 Wire brush and slag hammer Welding cable extensions with cable coupler and cable plug Design 25 mm ,3m long, plug 9 mm
2

Order no.(PG14) 551.0016.3 551.0025.3 551.0035.5 551.0050.5 551.0095.5

25 mm2,3m long, plug 13mm 25 mm2, , cable: 4 m electrode, 3 m ground, plug 9 Order no. 550.5506.0 (PG14) 25 mm , cable: 4 m electrode, 3 m ground, plug 13 Order no. 550.5503.0 (PG14)
2,

35 mm2,5m long, plug 13mm 50 mm ,5m long, plug 13mm

2

95 mm2,5m long, plug 13mm

35 mm2, , 2 x 4 m, plug 13 Order no. 550.5504.0 (PG14) 50 mm2, , 2 x 4 m, plug 13 Order no. 550.5505.0 (PG14)

Electrode holder Design Electrode holder 200 A Electrode holder 300 A Electrode holder 600 A Order no.(PG12) 550.0050.0 550.0051.0 550.0052.0

Electrode welding cable with electrode holder and plug ground clamp Design 25 mm2,4 m long,plug 9mm 25 mm ,4 m long,plug13mm
2

Order no.(PG14) 551.0210.0 551.0220.0 551.0230.0 551.0240.0 551.0250.0

35 mm2,4 m long,plug13mm 50 mm2,4 m long,plug13mm 70 mm2,4 m long,plug13mm

Design Quick earth plug 200 A, M 6 Quick earth plug 400 A,M10 Quick earth plug 600 A,M10

Order no.(PG12) 550.0102.0 550.0103.0 550.0104.0

Welding cable plug Design Cable plug 10-25 mm2, plug 9 Ground cables with ground clamp and plug Cable plug 35-50 mm2, plug 13 Cable plug 50-70 mm , plug 13
2

Order no.(PG12 665.7310.0 665.7320.0 665.7330.0 665.7340.0

Cable plug 70-95 mm2, plug 13 Welding cable couplers Cable coupler 10-25 mm2, for plug 9 mm Cable coupler 35-50 mm2, for plug 13 mm Cable coupler 50-70 mm2, for plug 13 mm Cable coupler 70-95 mm , for plug 13 mm
2

Design 25mm2, 4m long, plug 9mm 25mm , 4m long, plug 13mm

2

Order no.(PG14) 551.0110.0 551.0120.0 551.0130.0 551.0140.0 551.0150.0

665.7210.0 665.7220.0 665.7230.0 665.7240.0

35mm2, 4m long, plug 13mm 50mm2, 4m long, plug 13mm 70mm , 4 m long, plug13mm
2

70

ccessories
Special pliers MIG-MAG 4 functions in a single tool. Cutting the welding wire. Cleaning splashes off the shielding gas nozzle. Pulling off the gas nozzle. Releasing the contact tip. For torch ML 1500, ML 2500, Order no. 551.9070.0 (PG12) For torch ML 3600, MW 5500, Order no. 551.9071.0 (PG12) Protective shield Manual mask EN 166, PE black Order no. 550.5120.0 (PG12) MIG-MAG protective gloves Made of high-grade, durable leather. With wear-resistant seam. What a real welders glove should look like. Order no. 535.8210.0 (PG12) Welding glasses 10 spare glasses, 90 x110 mm, clear Order no. 535.8200.1(PG12) 5 welders protective glasses DIN EN 166/169, 90 x 110 mm, protective level 9 Order no. 535.8200.2 (PG12) 5 welders protective glasses DIN EN 166/169, 90 x 110 mm, protective level 10 Order no. 535.8200.3 (PG12) 5 welders protective glasses DIN EN 166/169, 90 x 110 mm, protective level 11 Order no. 535.8200.4 (PG12)

High-grade TIG gloves Supple leather for an optimum feel. Lightweight. Once you have welded in these, you wont want to take them off. Size M Order no. 535.8220.0 (PG 12) Size L Order no. 535.8220.1 (PG 12)

Pressure reducer Argon/mixed gas CO2 Order no. 570.9203.0 (PG14)

Slag hammer All steel, 350 g, order no. 550.5200.0 (PG12)

Wire brush, 3 rows of bristles, Order no. 550.5210.0 (PG12) Wire brush, VA, 3 rows of bristles, Order no. 550.5211.0 (PG12)

71

Electrode and TIG welding

Model Welding Setting range electrode 230 V Setting range electrode 400 V Weldable electrodes Setting range TIG 230 V Setting range TIG 400 V Setting No-load voltage Welding current at 100 % DC (25/40)C Welding current at 60 % DC (25/40)C Duty cycle at max. current (25/40)C Mains (table values valid for:) Mains voltage Mains frequency Mains fusing 230V / 400V (time-lag/C) Input power S1 (100 %) Input power S1 (at max I2) Mains current input (100 %) Mains current input (at max I2) Power factor (max I2) Power supply cable Mains plug (230/400V) Unit Protection class (IEC 529) Insulation class Cooling method Noise emission (EN 60974-1) Standard Identification Volume & weight Volume appr. (LxWxH) Weight Order number Technical equipment Welding current DC / AC Copper winding Inverter technology Sinus Power Management SPM Remote controllable Hotstart / Arc force / Anti stick Ignition: Contact / high frequency Gas management 2-stroke / 4-stroke Up-slope / Down-slope 2nd program current / end crater current H140 A/V A/V dia. mm A/V A/V Steps V A A % V Hz A kVA kVA A A cos phi mm IP dB(a) 5-140A / 20.2-25.6V up to 3.25 inf. variable max. 85 - / 80 - / 110 - / 30 Electrode 230 50 / 60 16 2.90 5.60 12.4 24.2 0.99 3x1.5 shock-proof 23 F F <70 EN 60974-1 CE , S 337x130x211 4.5 105.0140.0 X/X X X/X/X -/-/-/H150 5-150A / 20.2-26.0V up to 4.0 5-150A / 10.2-16.0V inf. variable max. 85 - / 115 - / 135 - / 40 Electrode 230 50 / 60 16 4.30 6.10 18.6 26.6 0.99 3x2.5 shock-proof 23 F F <70 EN 60974-1 CE , S 337x130x211 5.25 105.0150.0 X/X X X/X/X X/-/-/-/H180c 5-150A / 20.2-26.0V up to 4.0 5-180A / 10.2-17.2V inf. variable max. 85 - / 130 - / 150 - / 30 TIG 230 50 / 60 16 3.30 5.10 14.2 22.3 0.99 3x2.5 shock-proof 23 F F <70 EN 60974-1 CE , S 337x130x211 5.75 105.0180.0 X/X X X X/X/X X/X X/X X/X X/X H180t 5-150A / 20.2-26.0V up to 4.0 5-180A / 10.2-17.2V inf. variable max. 85 - / 130 - / 150 - / 30 TIG 230 50 / 60 16 3.30 5.10 14.2 22.3 0.99 3x2.5 shock-proof 23 F F <70 EN 60974-1 CE , S 337x130x211 6.5 105.0185.0 X/X X X X/X/X X/X X X/X X/X X/X

mm kg

MIG-MAG welding
Model Welding range Max. no-load voltage Voltage setting Duty cycle at max. current (25/40C) % Welding current 100%DC (25/40C) A Weldable wires steel Weldable wires aluminium Wire feed rate Mains voltage Mains frequency Mains fusing (time-lag/C) Max. power consumption S1 (230V) Max. input power S1 (400V) Input power S1 100% (230V) Input power S1 100% (400V) Max. mains current input (230V) Max. mains current input (400V) Current input I1 100% (230V) Current input I1 100% (400V) Power factor Protection class (IEC 529) Insulation class Cooling method Noise emission Standard Identification Ground power source (LxWxH) Ground wire feed case (LxWwH Power source weight Weight water cooling (filled) Weight wire feed case Feed unit Set wire diameter Torch type gas-cooled system Torch type water-cooled system Ground cable Cooling system (only for water cooling) Standard cooling power (1l/min) Maximum pressure Pump A/V V Steps mm dia. mm m/min V Hz A kVA kVA kVA kVA A A A A cos j IP F F dB(A) mm mm kg kg kg Rolls mm M 2020 30-140 / 15.5-21 36.8 6 25/15 70/55 0.6-0.8 1.0 1 - 23 1~230 50 / 60 16 3.7 0.8 16.3 3.6 0.85 (140A) 23 F F <70 EN 60974-1 CE, S 870x390x610 47 2 0.6 / 0.8 ML 1500 M 2040 25-170 / 15.2-22.5 34.9 6 25/15 90/70 0.6-0.8 1.0 1 - 23 1~230 / 2~400 50 / 60 16 3.8 5.2 1.2 16.4 13 3.1 0.84 (170A) 23 F F <70 EN 60974-1 CE, S 870x390x610 51 2 0.6 / 0.8 ML 1500 M 2060 25-210 / 15.2-24.5 36.9 6 25/15 105/85 0.6-1.0 1.0-1.2 1 - 23 1~230 / 2~400 50 / 60 16 5.0 6.4 1.8 21.6 16 4.4 0.89 (210A) 23 F F <70 EN 60974-1 CE, S 870x390x610 55 2 0.6 / 0.8 ML 1500 M 2080 30-230 / 15.5-25.5 32.6 7 30/20 140/115 0.6-1.0 1.0-1.2 1 - 23 3~400 50 / 60 16 6.8 2.3 9.8 3.3 0.89 (230A) 23 F F <70 EN 60974-1 CE, S 870x390x610 57 2 0.8 / 1.0 ML 2500 -

kW pmax (bar)

72

ISI 5 CL 3-140A / 20.1-25.6V 3-200A / 20.1-28.8V up to 5.0 3-140A / 10.1-15.6V 3-220A / 10.1-18.8V inf. variable 80 180/150 200/170 60/55 (Electrode) 1~230 / 3~400 50 / 60 16 5.9 8.3 8.5 12.0 0.89 5x2.5 shock-proof / CEE 16 23 F F <70 EN 60974-1 CE , S 370x210x295 16 115.0051.0 X/X X X X/X/X X/-

HT 180 AC/ DC 20-150A up to 4.0 3-180A inf. variable 70 k.A. / 110 A k.A. / 140 A k.A./ 35% TIG 1~230 50 / 60 16 1,0 3x1.5 shock-proof 23 F F <70 EN 60974-1 CE , S 480x185x326 13 250.0180.0 X/X X X X X/X/X X/X X X/X X/X X/X

HANDY-TIG 210 DC 3-160A / 20.1-26.4V up to 2.4 3-180A / 10.1-17.2V inf. variable 80.00 110/80 135/100 30/15 (TIG) 1~230 50 / 60 16 1.50 3.90 6.3 16.8 1.0 3x1.5 shock-proof 23 F F <70 EN 60974-1 CE , S 350x138x320 8.3 254.0210.0 X/X X X X X/X/X X/X X X/X X/X X/X

HANDY-TIG 210 AC/DC 3-160A / 20.1-26.4V up to 3.2 3-180A / 10.1-17.2V inf. variable 85.00 110/80 135/100 40/25 (TIG) 1~230 50 / 60 16 1.50 4.30 6.3 18.4 1.0 3x1.5 shock-proof 23 F F <70 EN 60974-1 CE , S 430x138x320 11.1 254.1210.0 X/X X X X X X/X/X X/X X X/X X/X X/X

CL 4P-F 20-130A / 20.8-25.2V 70-175A / 22.8-27.0V up to 4.0 -11 48 - 60 130/110 175/145 60/40 (Electrode) 1~230 / 2~400 50 / 60 16 / 25 5.6 8.8 13.9 22.0 0.71 (175A) 5x2.5 shock-proof / CEE 16 23 F F <70 EN 60974-1 CE 380x250x400 31 106.5005.0 -/X X ---/-/--

CL 5P-F 25-120A / 21-24.8V 45-200A / 21.8-28V up to 5.0 inf. variable 48 -60 150/125 200/170 60/40 (Electrode) 1~230 / 2~400 50 / 60 16 / 25 5.5 8.8 13.8 22.0 0.72 (200A) 5x2.5 shock-proof / CEE 16 23 F F <70 EN 60974-1 CE 450x310x440 49 106.5007.0 -/X X -/-/-

MIG-brazing
M 2090 30-290 / 15.5-28.5 37.2 12 30/20 160/135 0.6-1.2 1.0-1.2 1 - 25 3~400 50 / 60 16 10.8 2.8 15.6 4.1 0.89 (290A) 23 F F <70 EN 60974-1 CE, S 870x390x610 67 4 0.8 / 1.0 ML 2500 M 2095 25-350 / 15.3-31.5 42 24 30/20 185/160 0.6-1.2 1.0-1.6 1 - 25 3~400 50 / 60 25 14.9 4.5 21.5 6.5 0.89 (350A) 23 F F <70 EN 60974-1 CE, S 870x390x610 94 4 0.8 / 1.0 ML 3600 M 3050 25 - 350 / 15.3 - 31.5 42 24 45/30 k.A./210 0.6 - 1.6 1.0 - 1.6 0.1 - 25 3~400 50/60 25 15.4 6.7 22.3 9.7 0.89 (350A) 23 F F <70 EN 60974-1 CE,S 945 x 425 x 720 560 x 190 x 435 109 10.5 17 4 1.0 / 1.2 ML 3600 MW 5500 50 mm2, 4 m 1.1 3.5 Centrifugal pump M 3070 30 - 400 / 15.5 - 34 48 24 45/30 k.A./240 0.6 - 1.6 1.0 - 1.6 0.1 - 25 3~400 50/60 35 20 8.5 28.8 12.2 0.87 (400A) 23 F F <70 EN 60974-1 CE,S 945 x 425 x 720 560 x 190 x 435 126 10.5 17 4 1.0 / 1.2 ML 3600 MW 5500 50 mm2, 4 m 1.1 3.5 Centrifugal pump M 3030 automotive 30 - 260 / (11.4) 15.5 - 27 34 41 Digastep 45/35 180/160 0.6 - 1.2 1.0 - 1.2 0.1 - 25 3~400 50/60 16 9.7 5 14 7.2 0.87 (260A) 23 F F <70 EN 60974-1 CE,S 945 x 425 x 720 108.5 4 0.8 / 1.0 aluminium ML 2400 PM 35 mm2, 4 m -

73

MIG-MAG, TIG and electrode welding

Model Welding Welding range Max. no-load voltage Power setting Characteristic tendency Welding current at 100% DC (40C) Welding current at 60% DC (40C) Duty cycle at max. current (40C) Weldable wires steel Weldable wires aluminium Wire feed rate Mains Mains voltage Mains frequency Mains fusing (time-lag/C) Input power S1 100% Input power S1 60% Input power S1 at max. current Mains current input I1 100% Mains current input I1 60% Mains current input I1 at max. current Power factor (at max. current I2) Mains cable Mains plug Unit Protection class (IEC 529) Insulation class Cooling method Noise emission Standard Identification Weights and measurements Power source measurements (LxWxH) Power source weight Feed unit Set wire diameter Torch type /Electrode holder Ground cable * not as standard MIG / MAG 35-170 / 15.7-22.5 constant 100 120 25 0.6-0.8 1.0 1 - 25 A 1700 and CuSi TIG 5-150 / 10.2-16 60 inf. variable falling 110 130 35 1 Ph 230 10% 50 / 60 16 2.1 2.7 3.2 9.3 11.6 14.1 0.98 3 x 2.5 shock-proof 23 F F <70 EN 60974-1 CE, S 590x280x460 19.2 * WLT 17 EA, 4m * E cable 25 mm, 4m 25 mm2, 4m Electrode 25-150 / 21-26 falling 100 120 30 MIG / MAG 35-220 / 15.7-25.0 constant 150 170 15 0.6-1.0 1.0 - 1.2 1 - 25 A 2200 and CuSi TIG 5-200 / 10.2-18 60 inf. variable falling 150 170 35 1 Ph 230 10% 50 / 60 16 / 25 3.2 3.9 4.8 14 17 21 0.98 3x4 shock-proof / CEE 32 23 F F <70 EN 60974-1 CE, S 590x280x460 20.4 * WLT 26 EA, 4m * E cable 25 mm, 4m 25 mm2, 4m Electrode 25-200 / 21-28 falling 100 120 30 -

A/V V / DC A A % dia. mm dia. mm m/min V Hz A kVA kVA kVA A A A cos phi mm2 IP dB(A)

2.6 3.3 5.2 11.2 14.2 22.6

3.2 4.0 5.3 14.1 17.6 23

4.4 5.1 7.4 19 22 32

5.3 6.2 7.4 23 27 32

mm kg Rolls mm

2 0.8 - 1.0 ML 1500, 4m

2 0.8 - 1.0 ML 2400, 4m

Plasma cutting
Model Cutting Setting range cutting current Cutting current setting No-load voltage Cutting current at 100% DC (40C) Cutting current at 60% DC (40C) Duty cycle at max. current (40C) Mains Mains voltage (50/60Hz) Mains frequency Mains fusing (time-lag/C) Mains cable Mains plug Input power S1(at max. I2) Mains input power I1 (at max. I2) Unit Protection class (IEC 529) Insulation class Cooling method Noise emission Standard Identification Weights and measurements Measurements (LxWxH) Weight Standard equipment Torch type Ground cable Supplementary data Air pressure Air consumption Max. cutting thickness steel Max. cutting thickness aluminium Max. cutting thickness stainless steel Quality cut steel Quality cut aluminium Quality cut stainless steel Z 70 A V A A % V Hz A mm2 kVA A 22 - 70 inf. variable 495 50 70 60 3 Ph 400 10% 50 / 60 16 4 x 2.5 CEE 16 15.9 23 IP23 F F <70 EN 60974-1 CE , S 650 x 260 x 470 30.5 LCT 80 6m 25 mm2, 4 m bar l/min mm mm mm mm mm mm 5.5 - 7 170 22 17 18 17 12 14 Z 110 22 - 110 inf. variable 495 60 82 35 3 Ph 400 10% 50 / 60 32 4x4 CEE 32 30.5 44 IP23 F F <70 EN 60974-1 CE , S 650 x 260 x 470 31.5 LCT 150 6m 25 mm2, 4 m 5.5 - 7 200 37 27 30 32 22 24

dB(A)

mm kg

Sorry to say that all prices stated here are subject to addition of the statutory rate of value (added) tax - value (added) being the operative word in our case! Pricing status: July 2006, print status: June 2006 Subject to improvement and to the unavoidable possibility of human error.

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iQ
Lorch iQ for industry. Being industry qualified means exceeding expectations in the highly demanding industrial sector too. A word of explanation at the end of this book.
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Just 1 of 82,344 possibilities...

... a mobile S. Built for use byamedium-sized crane producer. 3 shifts, 8 welders, 4 nationalities. Fundamental decision: High-quality impulse seam, perfectly executed after just 3 setings. Plain text operator prompting in the weldersnative language. Trolley-mounted tocope with a travel distance of over 20 metres in the production hall. Portable: Used daily on the platform for thin sheet, but for 6 mm thick material below - hence the need for additional water cooling. Series production, shift working, repeat accuracy, operating clarity: What every producer has a right toexpect - from the mediumsized workshop through tothe biggest multinational corporation. 50 % of the systems weproduce are used in industry. Systems designed for just one purpose: Doing their designated job and delivering a unique standard of quality based on their performance and durability. Mobile or stationary.With wire feede case on the crane or at the fixture. Drawing on this wealth of experience, wewill tailor you a bespoke suit tofit your operation to perfection. iQ for your production.

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C
MIG-MAG system with synergetic Digastep. Setting the standard in its class.

P
Digital MIG_MAG intelligence. Unadulterated performance.

V
TIG inverterResearch and development for TIG welders.

S
Digital MIG-MAG pulse system.Far better. Far more productive.
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When you buy a Lorch system, we will provide you with all the knowledge you need. Our practical training courses offer

Process knowledge Adjustment knowledge System knowledge

On your own premises. Processing your actual orders. 1 or 2 hours are often enough for you to gain a solid grounding in the possibilities available to you and how to use them successfully. A highly valuable exercise even for the most experienced professional. Talk to your dealer to arrange your practical training course. We consider it a must. Your share of the costs is 69.- Euros per hour. Needless to say, we will not charge you any travel expenses. You will never regret it.

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Thanks