Contents
Notes on the use of these operating instructions
099-005325-EW501
3
1 Contents
1
Contents .................................................................................................................................................. 3
2 Safety instructions ................................................................................................................................. 6
2.1 Notes on the use of these operating instructions .......................................................................... 6
2.2 Explanation of icons ....................................................................................................................... 7
2.3 General .......................................................................................................................................... 8
2.4 Transport and installation ............................................................................................................ 12
2.4.1 Lifting by crane ............................................................................................................. 13
2.4.2 Ambient conditions ....................................................................................................... 14
2.4.2.1 In operation ................................................................................................... 14
2.4.2.2 Transport and storage ................................................................................... 14
3 Intended use ......................................................................................................................................... 15
3.1 Applications .................................................................................................................................. 15
3.1.1 MIG/MAG standard welding ......................................................................................... 15
3.1.1.1 forceArc ......................................................................................................... 15
3.1.1.2 rootArc ........................................................................................................... 15
3.1.2 MIG/MAG pulse welding ............................................................................................... 15
3.1.2.1 forceArc puls ................................................................................................. 15
3.1.2.2 rootArc puls ................................................................................................... 15
3.1.3 TIG (Liftarc) welding ..................................................................................................... 15
3.1.4 MMA welding ................................................................................................................ 15
3.1.4.1 Air arc gouging .............................................................................................. 15
3.1.5 Voltage reduction device – VRD machine version ....................................................... 15
3.2 Use and operation solely with the following machines ................................................................ 16
3.3 Documents which also apply ....................................................................................................... 17
3.3.1 Warranty ....................................................................................................................... 17
3.3.2 Declaration of Conformity ............................................................................................. 17
3.3.3 Welding in environments with increased electrical hazards ......................................... 17
3.3.4 Service documents (spare parts and circuit diagrams) ................................................ 17
3.3.5 Calibration/Validation ................................................................................................... 17
4 Machine description – quick overview .............................................................................................. 18
4.1 Front view .................................................................................................................................... 18
4.2 Rear view ..................................................................................................................................... 20
4.3 Rear view ..................................................................................................................................... 20
5 Design and function ............................................................................................................................. 22
5.1 General ........................................................................................................................................ 22
5.2 Installation .................................................................................................................................... 23
5.3 Machine cooling ........................................................................................................................... 23
5.4 Workpiece lead, general .............................................................................................................. 23
5.5 Notes on the installation of welding current leads ....................................................................... 24
5.6 Welding torch cooling system ...................................................................................................... 26
5.6.1 List of coolants .............................................................................................................. 26
5.6.2 Maximal hose package length ...................................................................................... 26
5.6.3 Adding coolant .............................................................................................................. 27
5.7 Mains connection ......................................................................................................................... 28
5.7.1 Mains configuration ...................................................................................................... 28
5.8 Intermediate hose package connection ....................................................................................... 29
5.9 Shielding gas supply (shielding gas cylinder for welding machine) ............................................. 30
5.9.1 Connection ................................................................................................................... 30
5.10 Adjusting the cable resistance ..................................................................................................... 32
5.11 MIG/MAG welding ........................................................................................................................ 34
5.11.1 Connection for workpiece lead ..................................................................................... 34
5.12 TIG welding .................................................................................................................................. 35
5.12.1 Welding torch connection ............................................................................................. 35
5.12.2 Connection for workpiece lead ..................................................................................... 36
5.13 MMA welding ............................................................................................................................... 37
5.13.1 Connecting the electrode holder and workpiece lead .................................................. 37