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ENGLISH
TOCe
-- 2 7 --
INTRODUCTION 28.....................................................
TECHNICAL DESCRIPTION 29...........................................
Wire feed unit MLC 302 29..........................................................
Technical data 30..................................................................
INSTALLATION 31......................................................
Connecting the welding hose 31......................................................
Connecting the welding current 31....................................................
Connecting the compressed air 31....................................................
NOTE! 31.........................................................................
Connecting the shielding gas 31......................................................
MAINTENANCE 32......................................................
Replacing the wire 32...............................................................
Cleaning 32.......................................................................
Ordering spare parts 32.............................................................
DIAGRAM 77............................................................
SPARE PARTS LIST 78...................................................
INTRODUCTION
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bm15d12e
INTRODUCTION
The MLC 302 is a component of the A9 semi--automatic series ”push--pull”--system.
This means that a motor driven wire feed unit pushes the wire through the welding
hose to the gun, and from there the compressed air motor in the welding gun pulls
the wire out to the contact tip. The push--pull system ensures smooth, problem--free
wire feed, which is especially important when welding soft consumables such as
aluminium and thin wires. It also permits the use of welding hoses up to 16 m in
length. It simplifies the work of the welder considerably and extends his working
radius, since the wire feed unit can also be separated from the power source.
Besides the drive motor, the wire feed unit comprises a connecting block for the
welding hose, brake hub for wire reels up to 300 mm in diameter, plus control
devices, i.e. solenoid valve for shielding gas, compressed air valve with filter
regulator and current relay.
The wire feed unit can be placed in a variety of positions. If equipped with a
counterbalance and/or turntable the MLC 302 can be made to swivel over the guide
journal on the power source. It can be fitted with a suspension device and
suspended over the work place. It can also be fitted with wheels (carriage) for
free --standing use and easy positioning on the floor or work bench.
MLC 302 is available in a version for connection to 42 V, 50/60 Hz.
WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is s afe.
FUMES AND GASES -- Can be d angerous to health
S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and
the general area.
ARC RAYS -- Can injure eyes and burn skin.
S Protect y our eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S Protect y our ears. Use ear defenders or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
TECHNICAL DESCRIPTION
-- 2 9 --bm15d12e
TECHNICAL DESCRIPTION
The MLC’s aluminium casing is divided vertically into two sections. One section,
which is protected by a screwed panel, contains the electrical and pneumatic
regulating equipment. The other section is covered at the top and side by a hinged
panel. In the closed position this panel is secured to the bottom panel by a snap lock.
This section contains the hub for the wire reel, the wire feed mechanism with electric
motor and connecting block for welding hose.
The rear panel has a grommet to allow the passage of the welding cable out of the
power source.
MLC 302 is fitted with a filter regulator. This drains automatically when the
compressed air system is switched off. The pressure is permanently set at 500 kPa
(5 kg/cm
2
).
Wire feed unit MLC 302
The motor driven wire feed unit is mounted on the output shaft of the electric motor
and comprises a driven feed roller and freewheeling pressure roller. The pressure
roller, which consists of a simple ball bearing, is mounted on a camshaft, which runs
in a needle bearing housed in the casing. Pressure is exerted on the wire by means
of torque applied to the camshaft by an adjustable spring mechanism.
The design of the wire feed unit insulates the welding wire from the outer casing.
The inlet and outlet nozzles are made of hardened steel. When welding with Æ1.6
mm wire the outlet nozzle must be removed from the wire feed unit. On the front
panel is a remote socket (M 26) to allow remote control of voltage. This requires a
thyristor regulated power source, e.g. LAH 315/500 or LUA 400.
WARNING!
Rotating parts can cause injury, take great care.
IMPORTANT!
To prevent the reel sliding off the hub: Lock the reel in place
by turning the red knob as shown on the warning label atta-
ched next to the hub.
TECHNICAL DESCRIPTION
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bm15d12e
Technical data
Connection data
Continuous A weighted
noise pressure level 58 dB
Voltage 42 V, 50/60 Hz
Power rating 85 VA
Control cable Conductor, type RDO 6x1 mm
2
Gas connection Hose nipple for Æ 6 mm hose
Air connection Coupling för 1/4” hose
Air pressure Min. 500 kPa (5 kg/cm
2
)
Welding current Max. 400 A at 60 % duty cycle
Wire feed speed Max. 15 m/min. Adjusted at welding gun
Wire diameter Æ 0.6--1.6 mm
Inlet nozzle Bore Æ 2.7 mm
Outlet nozzle Bore Æ 1.5 mm
Outlet nozzle must be removed with Æ 1.6 mm wire
Brake hub
intended for wire reel with:
External diameter Æ 300 mm
Hub diameter Æ 51.1 mm
Hub length 100 mm
Dimensions
Lxbxh 577x279x465 mm
Weight 18 kg
INSTALLATION
-- 3 1 --bm15d12e
INSTALLATION
Connecting the welding hose
1. Open the side of the wire feed unit that contains the wire feed mechanism. Undo
the locking screw on the connecting block.
2. Choose the appropriate inlet nozzle for the wire being used and push it securely
into the welding hose.
3. Connect the welding hose to the wire feed unit and tighten the locking screw on
the connecting block.
4. Remove the plastic cover from the gun housing, undo the locking screw and
push in the other end of the welding hose. Then tighten the locking screw.
5. Check that the welding hose connections are correctly positioned and that the
locking screws have been securely tightened. Refit the plastic cover.
Connecting the welding current
Connect the welding cable from the positive socket on the power supply to the
current terminal on the connecting block.
Connecting the compressed air
Remove the panel, which is secured to the casing by four screws. Pull the supply air
hose through the hole in the opposite side of the casing (next to the control cable)
and connect the compressed air hose directly to the nipple on the filter regulator.
Tighten the compressed air hose.
NOTE!
If the wire feed unit is suspended the filter regulator must be set in the vertical
position. This prevents any water remaining in the compressed air system from
reaching the welding gun and causing operating problems.
Rotate the filter regulator anticlockwise so that it is directly opposite the hole in the
casing intended for this purpose. Then tighten the filter regulator.
Connecting the shielding gas
Connect the shielding gas directly to the nipple on the solenoid valve.
WARNING
This product is intended for industrial use. In a domestic environment this product
may cause radio interference. It is the users responsibility to take adequate pre-
cautions.
MAINTENANCE
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bm15d12e
MAINTENANCE
Replacing the wire
The wire conduit is made of plastic and can be damaged by sharp objects. Remove
any burrs or sharp edges from the tip of the wire using a file, before feeding the new
wire into the wire conduit.
1. Release the pressure roller springs.
2. Withdraw any remaining wire from the conduit. Remove the wire reel.
3. Fit the new wire reel.
4. Straighten out the first 5--10 cm of the wire and file off any sharp edges from the
tip of the wire.
5. Make sure the correct size inlet nozzle is fitted to the welding hose.
6. Guide the wire into the wire feed unit. Make sure it passes through the grooves
in the feed rollers, into the outlet nozzle and then into the inlet nozzle of the wel-
ding hose. If welding with Æ 1,6 mm wire the outlet nozzle must first be removed.
7. Re--tension the pressure roller springs.
8. Fit the correct contact tip to the welding gun.
9. Switch on the power source, press the gun trigger and allow the wire to advance
through the welding hose and out of the contact tip.
Cleaning
When necessary clean the wire feed mechanism in the wire feed unit and the wire
conduit in the welding hose using compressed air. Clean the grooves in the feed
roller and pressure roller.
You should also clean the inlet and outlet nozzles of the wire feed mechanism.
Dismantle as follows:
1. Undo the screw on the connecting block using an Allen key, then remove the
welding hose.
2. Undo the two stop screws that hold the inlet and outlet nozzles in place and re-
move them.
3. Refit the nozzles after cleaning.
Ordering spare parts
When ordering please state the machine model, serial number, part n ame and part
number. This simplifies dispatch and ensures correct delivery.
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