LORCH M 2020 Operating instructions

Brand: LORCH

Model: M 2020

Category: Welding System

Type: Operating instructions

This manual is also suitable for

910.1053.1-12

Operation Manual

MIG/MAG Welding System

M-Series

1Pressure reducer

2Gas cylinder*

3Torch

4Tray area

5Handle

6Connections

7Operation panel

8Transport wheels

9Ground clamp

*) accessory

Depicted or described accessories are partly

not included at delivery.

Use and maintenance of welding and cutting

machines can be dangerous. Please draw

user´s attention to follow the safety precau-

tions to avoid injuries. Welding and cutting

machines must be used appropriate and

only by specialist staff. Please inform yours-

elf constantly about the valid safety precau-

tions and regulations of accident prevention

by working with this machine*.

Remove all flammable material from the wel-

ding 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 re-

moved.

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 at-

tention to protect other persons in the welding

area against arc-rays.

Please use absorbers or other systems to ab-

sorb the gases.

It is not possible to absorb all the gases correct-

ly 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 ser-

vice 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 wel-

ding.

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 trans-

port and fixind is 10°.

Seviceand repair work is permitted only to a trained elec-

trical specialist.

Keep attention to connect the ground cable near the wel-

ding location. Welding current through chains, ball-bearing

or steel-cables may destruct or melt it.

Secure yourself and the unit at higher or inclinational pla-

ces.

The machine may only be connected to a properly groun-

ded mains supply.

(three-phase four-wire system with grounded neutral con-

ductor or single phase-three-wire-system with grounded

neutral conductor)

Socket and extension cable must have a functional protec-

tive conductor.

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 -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 trans-

portation.

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..

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.

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.

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.

The sound level of the unit is smaller as 70 db(A) measured

at standard load conforming EN 60974 at the max. workpoint.

1 Safety precautions

2 Transportation

3 General regulation of use

4 Unit protection

5 Noise emission

This product is manufactured conform to the current EMC

standard. Please notice following items:

The unit is for welding under commercial or industrial con-

ditions (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 telecom-

munication

– 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 pro-

tect additionally.

The affected area can be bigger than your premises/pro-

perty depends of the building etc.

Please use the unit conform to the instructions of the manu-

facturer. The user is responsible for installation and use of the

machine. Furthermore the user is responsible to eliminate the

disturbances caused by electromagnetic fields.

6 Electromagnetic compatibility (EMC)

7 Technical data

type M 2020 M 2040 M 2060 M 2070

CuSi M 2080 M 2090 M 2095

welding range A/V 30-140/

15,5-21

25-170/

15,2-22,5 25-210/

15,2-24,5 15-150 /

14,8-21,5 30-230/

15,5-25,5 30-290/

15,5-28,5 25-350/

15,3-31,5

no load voltage

(max.) V36,8 34,9 36,9 27,5 32,6 37,2 42

voltage adjustment Stufen 6667712 24

duty cycle at max.

power (25 °C/

40 °C)

%25/15 25/15 25/15 -/40 30/20 30/20 30/20

Welding current at

100 % duty cycle

(25 °C/40 °C)

A70/55 90/70 105/85 -/100 140/115 160/135 185/160

weldable wire steel mm Ø 0,6-0,8 0,6-0,8 0,6-1,0 0,6-0,8 0,6-1,0 0,6-1,2 0,6-1,6

weldable wires:

CuSi3 mm Ø ---0,8-1,0 ---

weldable wire alu mm Ø 1,0 1,0 1,0-1,2 11,0-1,2 1,0-1,2 1,0-1,6

wire-feed speed m/min 1-23 1-23 1-23 1 - 23 1-23 1-25 1-25

mains voltage V1~ 230 1~ 230/

2~ 400 1~ 230/

2~ 400 3~ 400 3~ 400 3~ 400 3~ 400

mains frequency Hz 50/60 50/60 50/60 50/60 50/60 50/60 50/60

mains fuse tr/C 16 16 16 10 16 16 25

mains current input

(max.) A16,3 16,4 21,6 6,5 9,8 15,6 21,5

input power (max.) kVA 3,7 5,2 6,4 4,5 6,8 10,8 14,9

power factor cos ϕ0,85/140 A 0,84/170 A 0,89/210 A 0,89/150 A 0,89/230 A 0,89/290 A 0,89/350 A

cooling method FFFFFFF

insulation class FFFFFFF

protection class

(IEC 529) IP 23 IP 23 IP 23 IP 23 IP 23 IP 23 IP 23

dimensions,

approx. (LxWxH) mm

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

weight kg 47 51 55 66 57 67 94

torch type ML1500 ML1500 ML1500 ML 1500

CuSi ML2500 ML2500 ML3600

standard EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1

order number 2 rolls 202.2020.1 202.2040.1 202.2060.1 202.2070.1 202.2080.1 - -

order number 4 rolls - - 202.2061.4 202.2071.4 202.2081.4 202.2090.1 202.2095.1

Torch Connection

Plug in the centralplug 11 of the torch 3 into the central socket

10.

How to connect the ground cable

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.

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 con-

trols.

Please keep attention that the connections between ground

clamp and workpiece is constant.

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.

How to connect at the mains.

Plug in the plug into the mains socket. The fusing should be

corresponding to the technical data.

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.

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 in-

let nozzle 21 and the central connection 10.

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

8 Before operation

(R)

(S)

(T)

N(MP)

18 20

Double-roller feed

Quadruple-roller feed

18 18

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.

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.

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.

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 com-

pletely 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 cylin-

der is shown by the contentmanometer 25.

How to modify the machine for aluminium

welding

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 wire-

diameter. Please see at the torch spare list.

11 centralconnection

29 nipple for 4.0 mm and 4.7 external diameter

30 o-ring 3.5x1.5 mm to prevent gas outlet

31 nut

32 teflon and plastic liner

33 sustainpipe for teflon and plastic liner with 4 mm exter-

nal diameter it substitute the capillary pipe in the central

connection.

At 4.7 mm no sustainpipe is required.

19 wire-feed roll

Double-roller feed

Quadruple-roller feed

p p p

correct contact

pressure

too high

wrong wire-

feed roller

25 24

11 29 30 31 32 33 19

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

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 volt-

age range:

400 V (only with the M 2040, M 2060, M 2070, M 2080)

Operation via 400 V three-phase system.

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 cur-

rent 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

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 automati-

cally, 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 automati-

cally, 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

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 un-

dercuts are visible.

Increase the welding voltage with the step switch 35 when an

overly high welding seam is visible.

Control knob for wire-feed

The wire feed can be fine-tuned with the control knob 38. The

wire feed is automatically controlled dependent on the adjust-

ment 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 hap-

pen, 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.

9 Starting up

34 35

3940

34 35

373940

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.

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.

Further possible classification is by the type of arc. This

means the external form of the arc, is proneness to short-

circuiting, 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 weld-

ing processes through selection of the suitable arc voltage

and the respective speed of the wire-feed.

Types of arc

Short circuit arc

This type of arc is specially suitable for thin materials and po-

sitional welding due to a relative cool welding pool welded

with very short arc, low arc voltage and low current. The ma-

terial 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 de-

pends on the wire diameter and the gas mixture.

Transitional 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 possi-

ble.

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 occasion-

ally occur, which by the increase of the current at the moment

of the short circuiting lead to spattering when the arc is reignit-

ed.

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

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.

10 Basics of the MIG/MAG welding pro-

cess

Welding

Process Shielding Gas

Inert Active

MIG Helium (He)

Argon (Ar)

Mixtures of

Ar/He

MAG-C Carbon dioxide

100 % CO2

MAG-M Mixtures of

Ar/CO2

Ar/O2

arc

contact tip

gas nozzle

wire electrode

wire feed rolls

power source

workpiece

shielding gas

welding seam

wire diameter Long arc /

Spray arc Transitional

arc Short circuit

arc

mm A V A V A V

0,8 140…

180 23…

28 110…

150 18…

22 50…

130 14…

1,0 180…

250 24…

30 130…

200 18…

24 70…

160 16…

1,2 220…

320 25…

32 170…

250 19…

26 120…

200 17…

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.

Holding and manipulating the torch

)Metal shielded gas welding can be welded in all posi-

tions: 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 re-

quired. 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 experi-

ence 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.

Avoid extreme side to side movements to avoid that the weld-

ing 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.

Length of the arc

Welding with a longer arc reduces the penetration, the weld-

ing bead is wide and flat with increased spattering. The weld-

ing 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 re-

duced spattering. The welding material is transferred with

smaller drops as long as the welder is not welding with short

arc.

Length of the wire electrode

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 pene-

tration.

A shorter electrode end increases the amperage if the wire-

feed speed remains the same.

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.

welding direction draggingwelding direction pushing

long arc short arc

long electrode end short electrode end

11 Care and maintenance

12 Troubleshooting

Symptom Cause Remedy

Torch too hot contact tip is not tight check it

No function when torch

button is pressed nut of the torch hose is not tight tighten it

no connection of the control cable in the torch hose. check and change if necessary

overload of the machine and thermal protection is in

function (control lamp 39 indicates overload) allow machine to cool down at no load

Irregular wire feeding or

wire welds to the con-

tact tip

wire electrode is tight at the spool check and change if necessary

burr at the wire beginning cut the wire beginning again

Irregular wire feeding or

no wire feeding wrong contact pressure at the wire-feed rolls adjust it as described in the manual

torch defect check and change if necessary

no brass pipe in the central connection or is dirty install or clean the brass pipe

bad quality of welding wire check and change if necessary

rust formation at the welding wire check and change if necessary

torch liner is dirty inside disconnect the torch from the machine, screw

off the contact tip and clean the liner with com-

pressed air

torch liner is dejected check and change if necessary

motor brake adjusted to strong adjust as described in the manual

main rectifier defective check and replace, if required

Machine switches off duty cycle overloaded, control lamp 39 indicates

overload allow the machine to cool down

to less cooling of machine parts check the air in and outlet

Arc or short circuit be-

tween contact tip and

gas nozzle

spatter built up inside the gas nozzle remove it with special pliers

Unstable arc wrong diameter of contact tip or worn out change contact tip

No function of fan phase missing in the mains check machine at another socket and check

mains and fuses

Mains control lamp 40

does not light phase missing in the mains check machine at another socket and check

mains and fuses

No shielded gas gas cylinder empty replace it

defect torch check and replace it

pressure reducer dirty or defect check and replace it

valve of gas cylinder defect replace the gas cylinder

Shielding gas switches

not off valve of gas cylinder dirty or does not close remove torch and pressure reducer and clean it

with compressed air

Not sufficient shielded

gas wrong adjusted quantity of shielded gas adjust right as described in the manual

dirty pressure reducer check valve

torch, gashose blocked or not air-tight check and change if necessary

shielded gas is blow away from draught avoid draught

Less welding perform-

ance phase missing check machine at another socket and check

mains and fuses

poor ground connection ensure best contact between ground clamp

and workpiece

ground cable not right plugged in fasten ground cable by turning the plug to the

right

defect torch repair or replace it

main rectifier defective check and replace, if required

Hot plug of ground cable plug was not tightened by turning to the right check

Higher wire wear out at

wire-feeding unit wire rolls does not fit to the wire diameter install right wire rolls

wrong contact pressure at wire feeding adjust as described at the manual

Feed Variant, Steel/Aluminium

Only for EU countries.

Do not dispose of electric tools together with

household waste material!

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.

Lorch Schweißtechnik GmbH

Postfach 1160

D-71547 Auenwald

Germany

Telephone: +49(0)7191/503-0

Fax: +49(0)7191/503-199

We herewith declare that this product was manufactured con-

form 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

Wolfgang Grüb

Director

Lorch Schweißtechnik GmbH

Postfach 1160

D-71547 Auenwald Germany

Tel. +49(0)7191 503-0

Fax +49(0)7191 503-199

Internet:www.lorch.biz

E-Mail:[email protected]

Date of issue: 26.03.2008

Subject to change

13 Options

Table of variations Use Roll

alu Roll

steel

Standard 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

15 Service 16 Certificate of conformity

17 Publisher

Lorch Schweißtechnik 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

LORCH M 2020 Operating instructions

Brand: LORCH

Model: M 2020

Category: Welding System

Type: Operating instructions

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LORCH M 2020 Operating instructions

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LORCH M 2020 Operating instructions

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