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910.1053.

1-12

Operation Manual
MIG/MAG Welding System
M-Series

5
6
7

6
8

1
2
3
4
5
6

Pressure reducer
Gas cylinder*
Torch
Tray area
Handle
Connections

7 Operation panel
8 Transport wheels
9 Ground clamp
*) accessory
Depicted or described accessories are partly
not included at delivery.

1 Safety precautions
Use and maintenance of welding and cutting
machines can be dangerous. Please draw
users attention to follow the safety precautions to avoid injuries. Welding and cutting
machines must be used appropriate and
only by specialist staff. Please inform yourself constantly about the valid safety precautions and regulations of accident prevention
by working with this machine*.
Remove all flammable material from the welding area for fire prevention before welding.
Do not weld at containers which were filled up
before with flammable materials (fuel).
All inflammable material in the welding area
which could be inflamed by sparks must be removed.
Check after welding the place conforming UVV.
Do not expose the unit to rain, steam and do not
spray water in it.

Do not weld without protection shield. Keep attention to protect other persons in the welding
area against arc-rays.

Please use absorbers or other systems to absorb the gases.


It is not possible to absorb all the gases correctly please use a breathing apparatus.
Stop operation immediately at a defect or
damaging of the mains cable. Do not touch
the cable. Unplug the unit before each service or repair. Do not use the machine if the
mainscable is defect.
Place an extinguisher near the welding area.
Check the welding area against fire after welding.
Never try to repair a defect pressure reducer.
Replace the defect one.

Please transport and fix the welding unit only


on firm and even underground.
The max.allowable inclination angle for transport and fixind is 10.

Wear correct protective clothing, gloves and leather apron.


Protect the welding area with curtains or mobile walls
against rays.
Do not thaw frozen waterpipes or conductions with this
unit.
In high electrical risk areas (in confined spaces) it is only
allowed to use machines with S -sign.
Switch off the machine at breaks and close the valve of the
gas cylinder.
Secure the gas cylinder with a chain against falling over.
Please take off the gas cylinder from the machine for transportation.
Disconnect the plug from the mains before changing the
welding area or repairs at the machine.
*) available from Carl Heymanns-Verlag,
Luxemburger Str. 449, 50939 Cologne.
Please follow the current safety regulations corresponding to
your country..

2 Transportation
The welding equipment shall be transportet
only driving!
To lift up the welding equipment with
chains or ropes is not permitted.
Take off the gas bottle from the equipment
before the transport.

3 General regulation of use


This unit is for welding of steel, aluminium and their alloys as
well as for brazing with CuSi wires for commercial as well as
for industrial use.

4 Unit protection
This unit is protected electronically against overloading.
However the stepswitch should be not used under load.
Connect the workpiece with the groundcable to the machine.
Remove welding spatter from the inside of the gas nozzle with
a special pair of pliers. Spray with anti spatter spray inside the
gas nozzle to avoid adherence of spatters. Spray sloping to
avoid the obstruction of the gasoutlet.

5 Noise emission
The sound level of the unit is smaller as 70 db(A) measured
at standard load conforming EN 60974 at the max. workpoint.

Seviceand repair work is permitted only to a trained electrical specialist.


Keep attention to connect the ground cable near the welding location. Welding current through chains, ball-bearing
or steel-cables may destruct or melt it.
Secure yourself and the unit at higher or inclinational places.
The machine may only be connected to a properly grounded mains supply.
(three-phase four-wire system with grounded neutral conductor or single phase-three-wire-system with grounded
neutral conductor)
Socket and extension cable must have a functional protective conductor.

6 Electromagnetic compatibility (EMC)


This product is manufactured conform to the current EMC
standard. Please notice following items:
The unit is for welding under commercial or industrial conditions (CISPR 11 class A). The use in other surroundings
(for example in residential areas) may disturb other electric
devices.
During welding electromagnetic problems can be caused
at:
Mainscables, controlcables, connections for telecommunication
TV/Radio
Computer and other similar devices
Protection devises as for example alarm systems

Pacemakers and hearing aids


Devices for measure and calibrate
Devices with less protection against disturbances
If other devices are disturbed it may be necessary to protect additionally.
The affected area can be bigger than your premises/property depends of the building etc.
Please use the unit conform to the instructions of the manufacturer. The user is responsible for installation and use of the
machine. Furthermore the user is responsible to eliminate the
disturbances caused by electromagnetic fields.

7 Technical data
M 2080

M 2090

M 2095

25-210/
15,2-24,5
36,9

M 2070
CuSi
15-150 /
14,8-21,5
27,5

30-230/
15,5-25,5
32,6

30-290/
15,5-28,5
37,2

25-350/
15,3-31,5
42

6
25/15

6
25/15

7
-/40

7
30/20

12
30/20

24
30/20

70/55

90/70

105/85

-/100

140/115

160/135

185/160

mm
mm

0,6-0,8
-

0,6-0,8
-

0,6-1,0
-

0,6-0,8
0,8-1,0

0,6-1,0
-

0,6-1,2
-

0,6-1,6
-

1,0-1,2
1-23
1~ 230/
2~ 400
50/60
16
21,6

1
1 - 23
3~ 400

1,0-1,2
1-23
3~ 400

1,0-1,2
1-25
3~ 400

1,0-1,6
1-25
3~ 400

50/60
10
6,5

50/60
16
9,8

50/60
16
15,6

50/60
25
21,5

6,4
0,89/210 A
F
F
IP 23

4,5
0,89/150 A
F
F
IP 23

6,8
0,89/230 A
F
F
IP 23

10,8
0,89/290 A
F
F
IP 23

14,9
0,89/350 A
F
F
IP 23

type

M 2020

M 2040

M 2060

30-140/
15,5-21
36,8

25-170/
15,2-22,5
34,9

Stufen
%

6
25/15

welding range

A/V

no load voltage
(max.)
voltage adjustment
duty cycle at max.
power (25 C/
40 C)
Welding current at
100 % duty cycle
(25 C/40 C)
weldable wire steel
weldable wires:
CuSi3
weldable wire alu
wire-feed speed
mains voltage

mm
m/min
V

1,0
1-23
1~ 230

mains frequency
mains fuse
mains current input
(max.)
input power (max.)
power factor
cooling method
insulation class
protection class
(IEC 529)
dimensions,
approx. (LxWxH)
weight
torch type

Hz
tr/C
A

50/60
16
16,3

1,0
1-23
1~ 230/
2~ 400
50/60
16
16,4

3,7
0,85/140 A
F
F
IP 23

5,2
0,84/170 A
F
F
IP 23

standard
order number
order number

kVA
cos

mm
kg

2 rolls
4 rolls

870x390x610 870x390x610 870x390x610 870x390x610 870x390x610 870x390x610 870x390x610


47
ML1500

51
ML1500

55
ML1500

66
57
67
94
ML 1500
ML2500
ML2500
ML3600
CuSi
EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1
202.2020.1 202.2040.1 202.2060.1 202.2070.1 202.2080.1
202.2061.4 202.2071.4 202.2081.4 202.2090.1 202.2095.1

How to connect at the mains.

8 Before operation

Plug in the plug into the mains socket. The fusing should be
corresponding to the technical data.

Torch Connection
Plug in the centralplug 11 of the torch 3 into the central socket
10.

10
11

How to insert the wirespool


Open the lid at the machine and screw off the nut 17 from the
wire-coil pick-up 15.
Put on the wire coil at the wire-coil pick-up and pay attention
that the tappet is well insert at the coil 14.
By use of small wire coils please use the adapter (art.no.
620.9650.0).
Adjust the brake 16 by releasing the torch button the wire coil
do not continue to turn.

14
15
16

How to connect the ground cable

17

Connect the ground cable 13 at the groundconnection 12 and


fasten it turning to right and connect the ground clamp 9 to the
workpiece or at the welding table.

12

Insert of the wire electrode


Screw out the contact tip at the torch 3.
Open the lid at the machine.
The diameter of the wire should correspond to the diameter of
the feeding rolls. This is readable on the front at the built in
feeding roll 19.
Lift the lever 20 and thread in the wire electrode trough the inlet nozzle 21 and the central connection 10.

13

Double-roller feed

How to connect the ground clamp


Fasten the ground clamp 9 near the welding location, this
avoids that the current will flow trough machineparts or controls.
Please keep attention that the connections between ground
clamp and workpiece is constant.

20
1

18
3

10

L1(R)
L2(S)
L3(T)
N(MP)
PE

19

22

Quadruple-roller feed

18
20

21

18
20

10
21
1

Do not place the ground clamp on the welding machine or


gas cylinder, otherwise welding current is conducted via
the protective conductors and will destroy them.
Connect the ground clamp tightly to the welding bench or
to the workpiece.

19

22

Close the lever 18 and fasten it with the sweep levers 20.

Double-roller feed

4
5

18

20

22
Quadruple-roller feed

18

18

20

20

Put the gas cylinder 2 on the provided place at the back of the
machine and protect against falling by fastening the chain 27.
Open the gas valve 26 several times to blow out possible dirt
particles.
Turn the adjustment screw 28 of the pressure reducer 1 completely to the left.
Connect the pressure reducer 1 at the gas cylinder 2.
Connect the gas hose 23 at the pressure reducer. Open the
gascylinder and adjust the gas flow at the set screw 28 of the
pressure reducer while pressing the torch button.
The quantity will be shown at the flowmeter 24. This should
be approx. wire diameter x 10 l/min. The content of the cylinder is shown by the contentmanometer 25.

25 1 24

26

2
19

22

27

23

Switch on machine at main switch 34, stretch torch cable and


press buttons 22 on operating panel. Adjust the pressure at
the modulation screws 20 that the wire-feed rolls 19 even still
are turning by holding the wire coil. The wire should not be
clamped or deformed.

28

How to modify the machine for aluminium


welding
p

correct

contact
pressure
too high

wrong wirefeed roller

Hold down button 22 until wire projects about 20 mm from


torch neck.
Screw in the contact tip corresponding to the wirediameter
into the torch 3 and cut off the sticked out wire end.

Change the wire roll to a aluminium wire roll.


Change the steel-torch against an aluminiumtorch or resp.
change the wire liner against a teflon liner.
Remove the capillary tube 33 at the central connection.
Cut the teflon liner close to the end of the wire-feeding roll and
pull the brasstube over the teflon liner with the corresponding
length for stabilising it.
Fasten the torch and thread in the wire electrode.
The art.no. of the parts depends on the torch and wirediameter. Please see at the torch spare list.

11

29 30 31 32

33

19

How to connect the gas cylinder


Before opening the bottle the adjustment
screw 28 at the housing must be relieved, it
means, turned to the left, otherwise the
pressure-reducing vale could be damaged.

11
29
30
31
32
33

centralconnection
nipple for 4.0 mm and 4.7 external diameter
o-ring 3.5x1.5 mm to prevent gas outlet
nut
teflon and plastic liner
sustainpipe for teflon and plastic liner with 4 mm external diameter it substitute the capillary pipe in the central
connection.
At 4.7 mm no sustainpipe is required.
19 wire-feed roll

9 Starting up
The operational concept of the M-series units is very simple:
The wire feed automatically adjusts to the set welding
voltage.
The wire feed can be corrected manually.

Operating panel
35

34

36

230 V (only with the M 2020, M 2040, M 2060)


Operation via 230 V alternating current system. Use
the adapter cable included in the delivery (only with
M 2040, M 2060) for connection to the alternating current system).
0-1

(only with the M 2070, M 2090)


Operation via 400 V three-phase system.
0-1-2 (only with the M 2095)
Operation via 400 V three-phase system.
1: Low welding performance
2: High welding performance
The green mains control lamp 40 lights up.

Mode selector switch

40

39

38
35

34

37
36

Select the required welding mode with the mode selector


switch 36:
2-Stroke welding
Hold the torch switch pressed: The gas valve is
opened. The wire feed speed is controlled automatically, the arc is ignited.
Release the torch switch: The wire feed is stopped,
the automatically controlled burn-up period runs off.
The wire burns off so that it does not adhere to the
workpiece. The arc goes out.
4-Stroke welding
Press the torch switch briefly: The gas valve is
opened. The wire feed speed is controlled automatically, the arc is ignited.
Briefly press the torch switch again: The wire feed is
stopped, the automatically controlled burn-up period
runs off. The wire burns off so that it does not adhere
to the workpiece. The arc goes out.
Spot welding
All welding spots are carried out identical.
Press the torch switch: The arc remains for the period
of the adjusted spot welding duration and then goes
out. After the arc goes out: Release the torch switch.

Step switch
40

39

38
35

34

37
36

The step switch 35 is used for precision tuning of the welding


performance for the electrode and the material. Never
change the switch setting during welding.
Reduce the welding voltage with the step switch 35 when undercuts are visible.
Increase the welding voltage with the step switch 35 when an
overly high welding seam is visible.

Control knob for wire-feed

40

39

38

37

Main switch/M 2095: coarse Voltage-range


switch
Switch on the unit with the main switch/coarse voltage-range
switch 34 and select the required mains voltage/coarse voltage range:
400 V (only with the M 2040, M 2060, M 2070, M 2080)
Operation via 400 V three-phase system.

The wire feed can be fine-tuned with the control knob 38. The
wire feed is automatically controlled dependent on the adjustment of the welding stage. Set control knob 38 at least to the
center position when welding within the step range of 1-5 in
order to ensure sufficient wire feed.
Reduce the wire feed if the wire comes out pulsating.
Increase the wire feed if the arc is too hot.
!!! CAUTION : with a correction less than -2.5 it could happen, that the wire feed motor stops running !!!

Control knob for spot welding


The spot welding time is adjusted with control knob 37.

Overload indicator
When the yellow control lamp 39 lights up upon actuation of
the torch switch, the unit is subject to overload. Allow the unit
to cool down at no-load.
7

10 Basics of the MIG/MAG welding process


Principal of the MIG/MAG welding
The welding wire is fed from the wire coil to the contact tip due
to the wire-feeding rolls. The arc burns between the melting
wire electrode and the workpiece. The welding wire acts as
arc carrier and filler material. Shielding gas flows through the
gas nozzle and protects the arc against the atmospheregas.

wire feed rolls

power source

gas nozzle
contact tip
shielding gas
welding seam

workpiece

arc

At metal shielded gas welding both, inert and active gases are
used. The distinction is made between Metal Inert Gas (MIG)
and Metal Active Gas (MAG) welding.

MIG

Shielding Gas
Inert

Active

This type of arc is specially suitable for thin materials and positional welding due to a relative cool welding pool welded
with very short arc, low arc voltage and low current. The material transfer takes place within the short circuit.
This cycle is repeated again and again so the short circuit and
the arcing period is constantly alternating.
The transition from the short circuit to spray arc depends on the wire diameter and the gas mixture.

Transitional arc

Long arc
Long arcs are typical at welding at the higher ampere range
under carbondioxid and gases with a high CO2 content. It is
not particularly suitable for positional welding. In this type of
arc large drops are formed which falls into the welding pool
mainly by force of gravity. Due to that short circuits occasionally occur, which by the increase of the current at the moment
of the short circuiting lead to spattering when the arc is reignited.

Spray arc
The spray arc is not suitable for positional welding, due to the
extremely liquid nature of the welding pool. The spraying arc
forms by welding at the higher range of ampere using inert
gas or mixtures with high argon content. The most typical
characteristic of the spray arc is the short circuit free transfer
of extremely fine droplets.

Working range at MAG welding

Helium (He)
Argon (Ar)
Mixtures of
Ar/He

MAG-C

Carbon dioxide
100 % CO2

MAG-M

Mixtures of
Ar/CO2
Ar/O2

Further possible classification is by the type of arc. This


means the external form of the arc, is proneness to shortcircuiting, and the way of transfer to the workpiece.
It is not possible to select the arc force to each individual
welding process. This is only limited possible for example at
the short circuiting arc.
Short-arc welding is possible with all shielded metal arc welding processes through selection of the suitable arc voltage
and the respective speed of the wire-feed.

Short circuit arc

With continuously increasing current, the limit range from


short arc to transition arc is achieved. The material transfer
takes place partly within the short circuit and partly out of it.
The transition arc is a critical current range, characterised by
intensive spattering. This range should be avoided, if possible.

wire electrode

Welding
Process

Types of arc

wire diameter

Long arc /
Spray arc

Transitional
arc

Short circuit
arc

mm

0,8

140 23
180
28

110
150

18
22

50
130

14
18

1,0

180
250

24
30

130 18
200
24

70
160

16
19

1,2

220
320

25
32

170 19
250
26

120 17
200
20

Favourable welding characteristic are only possible if voltage and


current are correctly adjusted.
CO2 requires an arc voltage approx. 3 V higher than gas mixtures
with a high argon content.

Principle of msg-soldering
The process of msg-soldering is very similar to the proc-ess
of msg-welding. Because of the lower temperature,the base
material is not fuzed but jointed by melting thesolder which
coates the materials.

Holding and manipulating the torch

Metal shielded gas welding can be welded in all positions: horizontal, vertical-down, vertical-up, overhead
and in horizontal-vertical position.
At horizontal welding hold the torch vertical to the workpiece
(neutral torch position) or up to 30 pushing the torch. At
thicker welds, a slight dragging motion is sometimes used.
For best depth of penetration and covering of shielded gas is
the neutral position of the torch the most suitable one. Please
notice if the torch is tilted to far, it could be that possible that
air will be sucked into the shielded gas atmosphere (injection
effect).
At vertical and overhead welding a slight pushing motion is required. Vertical down welding is most used for thin materials,
for this kind of weld hold the torch at the neutral or slightly
dragging position. For this kind of welding is some experience required cause the welding pool could run ahead and
cause some lacks welding. With thicker material there is a
danger of lacks of fusion cause the welding pool is very liquid
due to high voltage.

Length of the arc


Welding with a longer arc reduces the penetration, the welding bead is wide and flat with increased spattering. The welding material is transferred with slightly larger drops than at
welding with a shorter arc.
Welding with a shorter arc (at the same amperage) increases
the penetration, the welding bead is narrow and high with reduced spattering. The welding material is transferred with
smaller drops as long as the welder is not welding with short
arc.

long arc

short arc

Length of the wire electrode

welding direction pushing

welding direction dragging

The distance between the torch and the workpiece should be


10 -12 times the diameter of the wire. Altering the distance of
the torch will influence the length of the electrode end.
A longer electrode end reduces the amperage and the penetration.
A shorter electrode end increases the amperage if the wirefeed speed remains the same.

Avoid extreme side to side movements to avoid that the welding pool will be damed up in front of the arc. This could cause
lacks of fusion due to the welding pool flows ahead of the
welding spot. The side to side motion should only be as wide
as is necessary to reach both sides of the joint. If the joint is
wide enough you should weld two parallel string beads.
At vertical-up position the side to side motion should describe
the shape of an open triangle.
long electrode end

short electrode end

11 Care and maintenance


Please keep attention to the current safety regulations at all
care and maintenance works.
The machine requires minimum of care and maintenance.
Only a few items should be checked to ensure a trouble free
long term operation.

Please check regularly the mains plug , mains cable,


torch as well as the ground connection for damages.
Once or twice a year please clean the machine with dry
low compressed air. Switch off the machine and pull out
the plug first. Open the case of the machine and clean
also inside - please avoid to blow directly onto
electronic parts - they could be damaged.

12 Troubleshooting
Symptom
Torch too hot
No function when torch
button is pressed

Cause
contact tip is not tight
nut of the torch hose is not tight
no connection of the control cable in the torch hose.
overload of the machine and thermal protection is in
function (control lamp 39 indicates overload)
Irregular wire feeding or wire electrode is tight at the spool
wire welds to the con- burr at the wire beginning
tact tip
Irregular wire feeding or wrong contact pressure at the wire-feed rolls
no wire feeding
torch defect
no brass pipe in the central connection or is dirty
bad quality of welding wire
rust formation at the welding wire
torch liner is dirty inside

Machine switches off

Arc or short circuit between contact tip and


gas nozzle
Unstable arc
No function of fan
Mains control lamp 40
does not light
No shielded gas

Shielding gas switches


not off
Not sufficient shielded
gas

Less welding performance

torch liner is dejected


motor brake adjusted to strong
main rectifier defective
duty cycle overloaded, control lamp 39 indicates
overload
to less cooling of machine parts
spatter built up inside the gas nozzle

wrong diameter of contact tip or worn out


phase missing in the mains
phase missing in the mains
gas cylinder empty
defect torch
pressure reducer dirty or defect
valve of gas cylinder defect
valve of gas cylinder dirty or does not close
wrong adjusted quantity of shielded gas
dirty pressure reducer
torch, gashose blocked or not air-tight
shielded gas is blow away from draught
phase missing
poor ground connection
ground cable not right plugged in

defect torch
main rectifier defective
Hot plug of ground cable plug was not tightened by turning to the right
Higher wire wear out at wire rolls does not fit to the wire diameter
wire-feeding unit
wrong contact pressure at wire feeding

10

Remedy
check it
tighten it
check and change if necessary
allow machine to cool down at no load
check and change if necessary
cut the wire beginning again
adjust it as described in the manual
check and change if necessary
install or clean the brass pipe
check and change if necessary
check and change if necessary
disconnect the torch from the machine, screw
off the contact tip and clean the liner with compressed air
check and change if necessary
adjust as described in the manual
check and replace, if required
allow the machine to cool down
check the air in and outlet
remove it with special pliers

change contact tip


check machine at another socket and check
mains and fuses
check machine at another socket and check
mains and fuses
replace it
check and replace it
check and replace it
replace the gas cylinder
remove torch and pressure reducer and clean it
with compressed air
adjust right as described in the manual
check valve
check and change if necessary
avoid draught
check machine at another socket and check
mains and fuses
ensure best contact between ground clamp
and workpiece
fasten ground cable by turning the plug to the
right
repair or replace it
check and replace, if required
check
install right wire rolls
adjust as described at the manual

13 Options
Feed Variant, Steel/Aluminium
Table of variations
Standard

Roll
alu

Use

Roll
steel

Standard at 2 rolls feeding units. Suitable for steel and aluminium, depending
on wire-feed roller in use.
Standard at 4 rolls feeding units. Due to the straightening effect of the roll less
wire friction in the torch. For use with thicker or hard wires.

14 Disposal
Only for EU countries.
Do not dispose of electric tools together with
household waste material!

15 Service
Lorch Schweitechnik GmbH
Postfach 1160
D-71547 Auenwald
Germany
Telephone: +49(0)7191/503-0
Fax:
+49(0)7191/503-199

In observance of European Directive 2002/96/EC on waste,


electrical and electronic equipment and its implementation in
accordance with national law, electric tools that have reached
the end of their service life must be collected separately and
returned to an environmentally compatible recycling facility.

16

Certificate of conformity

We herewith declare that this product was manufactured conform to following standards: EN 60 974-1/-10, EN 61 000-3-2,
EN 61 000-3-3, conform to the guidelines 2006/95/EG,
2004/108/EG
08
Wolfgang Grb
Director

Lorch Schweitechnik GmbH

17 Publisher
Lorch Schweitechnik GmbH
Postfach 1160
D-71547 Auenwald Germany

Date of issue: 26.03.2008

Tel. +49(0)7191 503-0


Fax +49(0)7191 503-199
Internet:www.lorch.biz
E-Mail:info@lorch.biz

Subject to change

11

Lorch Schweitechnik GmbH Postfach 1160 D-71547 Auenwald Germany


Tel. +49 (0)7191 503-0 Fax +49 (0)7191 503-199 info@lorch.biz www.lorch.biz