Content
1
Content
1. Introduction ................................................................................................................................................... 2
2. Safety instructions ....................................................................................................................................... 3
2.1 Safety instructions before introduction ....................................................................................... 4
2.2 Accident prevention ........................................................................................................................... 4
2.2.1 Safety instructions ......................................................................................................................... 4
2.3 Duty cycle ............................................................................................................................................. 6
2.3.1 Filter attachment ........................................................................................................................... 6
2.4 Instructions to avoid interference .................................................................................................. 6
2.4.1 Evaluation of the installation site ............................................................................................. 7
2.4.2 Procedures to reduce emitted interference ............................................................................ 7
3. Introduction ................................................................................................................................................... 9
4. Controls and displays ................................................................................................................................ 10
5. Manual electrode welding operation .................................................................................................... 13
5.1 To perform the Basic settings ........................................................................................................ 13
5.2 Hotstart settings for the welding current and the parameter ............................................. 14
5.3 Energy regulation with remote controller ................................................................................. 15
6. TIG (WIG) welding ...................................................................................................................................... 16
7. Technical data MobiARC 180 cel ........................................................................................................... 17
8. Technical Data MobiARC 280 cel ± ....................................................................................................... 18
9. Maintenance ................................................................................................................................................ 19
10. Spare parts ............................................................................................................................................... 20
11. Circuit diagrams ..................................................................................................................................... 24
12. Conformity Attestation for MobiARC 280 cel ............................................................................... 28
13. Conformity Attestation MobiARC 280 cel +- ................................................................................ 29
Introduction
2
1. Introduction
MERKLE welding units are capital equipment of special
class. We set high standards in the field of quality and
reliability. Technical innovation and permanent further
development of reliable technique are naturally for us.
Specialised knowledge is premise for handling the
welding units. Safety instructions are defined in detail.
You as responsible user, have to follow the instructions
of the operating manual.
The operating manual is addressed to qualified welding
experts. Only skilled technical staff has to carry out the
service and repair work.
This documentation explains the safety instructions, the
functions, the operation and the maintenance of your
welding unit. In the appendix you find tables with
reference values for your instrument settings,
schematic diagrams, conformity attestation and lists of
important equipment.
Safety instructions
3
2. Safety instructions
The follow safety instructions serve for your own safety as well as prevention of damages at
your welding unit. For this reason, please read the safety instruction heedful before starting and
follow the safety instruction during the work.
Protect yourself and your surroundings against arc loads!
• Arc loads can induce irreversible damages on your eyes as well as
flash burns at your skin. For this reason you have to use a shield with
proper protection class and wear not inflammable clothes.
• Insulate your work area from other people, so that arise no risk
through the arc loads.
Decide arrangements for prevention of burnings!
• Remove inflammable objects out of your work area.
• Do not weld in the area with inflammable atmosphere.
• Make sure that possible burnings can be fast erased (fire drencher,
fire blanket).
Pay attention to the handling of the gas bottles!
• Gas bottles have to put in a proper holder and it have to secured
against tilting over.
• Gas bottles with damaged or leaky valves are to be put out of action
immediately.
• Gas bottles are only with screwed protection cap transportable.
• After end of work you have to close the bottle valve.
Do not operate the machine in wet surroundings!
• Infiltrated wetness can induce electric shock and damage your
machine.
Safety instructions
4
2.1
Safety instructions before introduction
The welding unit is build after recognized standards. Safe works are nevertheless only possible if
you read the operating instructions and the safety regulations contained in it entirely and obey
strictly. Install yourselves by trained staff of our establishments or appointed dealers.
2.2
Accident prevention
The accident prevention regulation is applied for MMA stick electrode and TIG welding unit,
model MobiARC 280 cel.
BGR 500 section 2.26 (earlier VGB 15) *welding, cutting and allied processes
A copy of this regulation should be readily accessible in every welding shop. The stipulations of
this regulation are to be observed in the interests of safe and correct welding operation.
* Available from the trade association responsible or Carl Heymanns-Verlag,
Luxemburger Straße 449, 50939 Cologne.
2.2.1
Safety instructions
This unit is manufactured according to the requirements and stipulations of EN 60974.1 / VDE
0544 part 1. BGR 500 (earlier VBG 15) of the trade association for engineering and electrical
engineering are as well valid.
Welding, cutting and allied working process
1) In cause of an accident you have to cut the mains from the welding power source
immediately.
2) You have to deactivate the machine from mains and it has to be checked from skilled expert
or it has to be checked from our service staff if it arise electrical contact voltage at the case.
3) If you have repair or upgrade work, you will cut the mains before you open the case.
4) Repair work may only be carried out by a skilled electrician or by our Service Department.
5) You have to check your machine, your welding torch and the mains plug for external
damages before every introduction.
6) Personal protective equipment in accordance with DIN EN 175, DIN EN 379 and
DIN EN 169.
The welder has to protect his complete body against radiation and burnings through protective
clothes and face protection during the work. In the process you have to wear gauntlets, aprons,
welding shield with protective filter (DIN EN 470-1 and BGR 189). You must not wear synthetic
clothes or sneakers instead you should wear high shoes and you have to wear a headgear if
necessary. The special equipment must be in accordance with the aforesaid and recognized
standards if you use that.
Safety instructions
5
As additional protection for the eyes against UV radiation, safety goggles with side
shields and corresponding face protection in accordance with BGR 192 and BGI 553
must be worn. Accident prevention regulation BGR 500 stipulates that it is the
responsibility of the employer to provide suitable personal protective equipment, while
§ 28 stipulates that it is the responsibility of the insured to wear suitable clothing.
7) Protection during welding with increased electrical hazard
Welding rectifier and welding power source have to be designed with „S“ after EN 60974-1
and BGI 534, if it appears direct current (DC) or alternating current (AC). Use insulating
materials against electrical contact as well as wet bottoms. You have to wear dry and
undamaged work clothes as well gauntlets and shoes with rubber sole. Vent the rooms,
install possible suctions and wear gas masks if it necessary (see detailed statement BGR 500
and BGI 533 section 5).
8) In order to prevent stray currents and the effects thereof (e.g. destruction of electrical
protective ground conductors), the welding return cable (workpiece cable) must be connected
directly to the workpiece to be welded or to the table (e.g. welding table, grid type welding
table, workbench, supporting the workpiece (see BGR 500). When installing the ground
connection, assure that there is a good electrical contact (remove rust, paint, etc.).
9) During the welding pauses, the welding torch is to be laid down on an insulated surface or
hang up in such a way that it is not in contact with the workpiece and is support connected
to the welding power source (see BGR 500). In the case of longer work pauses, the welding
unit must be switched off and the gas cylinder valve must be closed.
10) The shielding cylinder must always be protected against tumble down using a safety chain.
11) Under no circumstances the unit may be put into operation while it is opened. Apart from
safety regulations, sufficient cooling of the electrical components provided by the fan
cannot be guaranteed.
12) In accordance with BGR 500, persons in the vicinity of the arc must also be informed of the
hazards and protected against them. Safety partitions (“welding safety curtains”) must be
erected in accordance with DIN EN 1598.
13) No welding work may be carried out on containers in which gases, fuels mineral oils or
similar substances have been stored. (explosion hazard). See §31 UVV BGR 500ÖEven if
they have been empty for a long timeÕ See § 31 of accident prevention regulation BGR
500.
14) Welds which will be subjected to high loads and which need to meet specific safety
requirements may only be carried out by specially trained and qualified welders.
Safety instructions
6
15) Never bring the torch to your face. When the torch switch be unintentional put on is it
possible that you will be injured by the wire.
16) In areas at particularly high risk of fire, the welder must obtain a welding permit and have
this on his person throughout the duration of the welding work. On completion of welding, a
fireguard must be delegated to ensure fire protection.
17) Ventilation measures must be applied in accordance with BGI 553 section 9.
18) The hazard to eyesight must be indicated by means of a sign at the workplace „Caution! Do
not look into the arc!”
2.3
Duty cycle
The duty cycle measurings have been carried out in accordance with EN 60974-1 / VDE 0544
part 1 (10 min working period).
60% duty cycle means:
After 6 minutes welding period must be carried out a welding pause from 4 minutes.
The electrical components are thermally protected against overheating.
2.3.1
Filter attachment
The duty cycle from the unit will be reduced if you use filter attachment. Though is the air
permeability of the filter mats important. Entscheidend ist dabei die Luftdurchlässigkeit der
Filtermatten. The frequency of cleaning is dependent from the degree of utilisation and from the
workplace relationships. If you change the filter mats, you have to use only the original filter
mats with the article number 005.0.1048.
!!! If you ignore this statement, the warranty claim will be voided!!!
2.4
Instructions to avoid interference
The welding unit has been manufactured in accordance with the requirements of guideline EN
50199 regarding electromagnetic compatibility. It is nonetheless the responsibility of the user to
ensure that the welding equipment is installed and operated in accordance with the
manufacturer instructions. If electromagnetic interference is detected, it is the responsibility of
the users of the welding equipment to find a solution with the technical assistance of the
manufacturer´s. In some cases, it may be sufficient simply to ground the welding current circuit.
In other cases, it may be necessary to build a complete shield for the welding power source and
workpiece using the input filters. In all cases, electromagnetic interference must be reduced to
avoid any possible malfunctions.
Note: For safety reasons, the welding current circuit may or may not be grounded. No
modifications may be made to the grounding without the approval of an expert who is able to
determine whether the changes might increase the risk of accidents, e.g. by allowing parallel
welding current return paths which could destroy the ground conductors of other equipment.
Further instructions are contained in TEC 974-XX "Arc welding equipment – installation and
use".
Safety instructions
7
2.4.1
Evaluation of the installation site
Before installing the welding equipment, the user must evaluate potential electromagnetic
problems in the vicinity. The following must be considered:
¾ Other power cables, signal and telecommunication cables above, below and next to
the welding equipment.
¾ Radio and television transmitters and receivers.
¾ Computer and other control devices.
¾ The health of the peoples in vicinity, for example the use of pacemakers and hearing
aids.
¾ Calibration and measuring equipment
¾ Interference immunity of other devices in the vicinity. The user must ensure the
electromagnetic compatibility of other devices used in the vicinity. This may require
additional safety measures.
2.4.2
Procedures to reduce emitted interference
a) Mains supply
Welding equipment is to be connected to the mains in compliance with the
recommendations of the manufacturer. If interference occurs, it may be necessary to
take additional precautions, e.g. filters for the mains connection. Make sure that the
power cable of welding equipment is installed in a fixed position shielded by means of a
metal conduit or similar. The entire length of the shield must be electrically connected.
The shield must be connected to the welding power source in the way to obtain a good
electrical contact between the metal conduit and the housing of the welding unit.
b) Maintenance of the welding equipment
Welding equipment must be maintained regularly in accordance with the
recommendations of the manufacturer. All access and service doors and covers must be
closed and fastened securely when the welding equipment is in operation. No
modifications whatsoever may be made to welding equipment with the exception of
modifications and adjustments specified in the manufacturer´s operating instructions.
Safety instructions
8
c) Welding cables
Welding cables should be kept as short as possible and routed close together on or near
the floor.
b) Equipotential
It is available to interconnect all metallic parts in and next to the welding equipment.
Metallic parts connected to the workpiece can, however, increase the risk of the welder
receiving an electric shock by touching these metallic parts and the electrode
simultaneously. The welder must be electrically insulated against all these connected
metallic parts.
c) Grounding the workpiece
If the workpiece is not connected to the ground for electrical safety reasons, or due to
the size and position of the workpiece, e.g. steel structure or outer wall of a ship,
grounding the workpiece may in some cases, but not all, reduce emitted interference. It
must be ensured that grounding the workpiece will not increase the risk of accidents for
the user and cannot cause the destruction of other electrical equipment. If necessary,
the grounding of the workpiece must be carried out by means of a direct connection to
the workpiece. In countries where a direct connection is prohibited, the connection must
be made by means of suitable reactors, selected in accordance with national regulations.
d) Shielding
Selective shielding of other cables and devices in the vicinity can reduce interference
problems. For special applications, it may be worth considering shielding the entire
welding system.
Introduction
9
3. Introduction
The unit must be secured against unintentional fall down. The air intakes must be free otherwise
there is danger of overheating. Make sure that no metallic abrasive dusts can be absorbed with
the cooling air. Metallic abrasive dusts are electrically conductive and these can lead to internal
arcing. These internal arcing can damage the device.
Attention! If extension cable be used:
• Only use lines with a minimum diameter of 2.5 mm².
• Unroll the entire cable drum (hazard of overheating)
Attention! If it be put into operation with a power unit:
• The rated power output of the power unit must be at least 10%
greater than the maximal power input of the welding unit.
• The open circuit voltage of the power unit must be regulated
otherwise stress peaks can damage the unit.
Controls
10
4. Controls and displays
You learn in this section, the controls and the displays about their welding unit and gain a first
instruction to its handling. The following elements are present on the control panel:
1
2
3
4
5
Step switch for selection the operating mode
Status display
Operating mode display
Adjusting knob withPush Button
Multi functional display
Controls
11
Step switch for selection the operating mode
You can choose the operating mode with the step switch as well as call the function to change
the parameter. The individual switch settings are assigned to the following functions:
Settings for display: current-, voltage- or combi display
Energy regulation on control panel / with remote controller
Decrease time when TIG welding
(Introduction by pulling up the
torch)
TIG (WIG) welding operation (with Lift-Arc-Z)
Manual electrode welding operation
Settings for hotstart current
Settings for hotstart time
Selection of electrode
Attetion! In the switch position and is the welding voltage to the
sockets available.
Status display / operating mode display
The control lamps of the status display and the operating mode display furnish important
information about the active operating status and the settings. The meaning of the displays will
be described below.
Function „open circuit voltage<24V“ is active (option)
Power supply available, unit is switched on
Welding voltage is switched on
Interference display: unit is not ready
Overheat display: Power unit is overheated
Characteristic line for rutile infolded electrodes is dialled
Characteristic line for basic infolded electrodes is dialled
Characteristic line for electrodes with cellulose coating is
dialled
Energy regulation with remote controller
Controls
12
Multi function display
The multi function display is served to display of welding parameter and machine settings. It is
consist of digital display as well as control lamps. The meaning of the display will be described
below.
Display of current in ampere
Display of voltage in volt
Display of times in seconds
Percental display refer to welding current I1
The last welding worth will be showed if the „HOLD” lamp is shining.
Short text messages on Display
You can see short text messages immediate after activate the unit as well as after active the
operating selector switch on the display. The meaning of these messages will be described
below.
F r o
Energy regulation on control panel
Error messages will be seem on display which it makes possible to find the errors fast.
U E r
Voltage errors
U E T
Overheat power unit
4
Control knob with Push Button Function
You can change the parameter with the endless rotary knob. The switch function is integrated in
the control knob. The switch will be active if you press it. It will be overcome a perceptible
pressure point.
Manual electrode welding operation
13
5. Manual electrode welding operation
The welding units with the type MobiARC 280 cel can be used with only few settings and have
available a maximum for ease of use. These will be detailed in this chapter. The control panel
have available few and manageable controls for this reason it is easy to learn the controls
handling.
Establish the readiness for operation
• Put the mains plug into the power outlet.
• Plug the electrode cable and the ground cable.
Rutile infolded Stabelectroden (RR, RB, RC)
Electrode cable have to be plugged in the with „+“ marked socket,
ground cable have to be plugged in the with „-“ marked socket.
Basic infolded Stabelectroden (Bas, B, KB…)
Stabelectroden with cellulose coating (C, CEL)
Electrode cable have to be plugged in the with „-“ marked socket,
ground cable have to be plugged in the with „+“ marked socket.
• Lock the bayonet lock. Fixate the pole terminal of the ground cable
at the workpiece. The contact point must be cleared of paintworks,
layers of fat and oxide layers.
• Switch on the unit.
After starting the unit starts the run up phase. These begin with a lamp test (all lamps on the
control panel light up simultaneously short). Up next on display the information of the
software, the plant system as well as the machine settings as short text message.
5.1
To perform the Basic settings
The welding unit have available special attuned characteristic lines for different electrode types
thereof results ideal arc behaviour. This has the advantage that many other important Settings
are omitted, because characteristic lines present functions as for instance the functions of
current readjustment with short arc. Therefore, the welder has to carry out only few basic
settings.
Manual electrode welding operation
14
Choose the electrode type
• Carry the step switch 1 in position and adjust the
appropriate electrode type with the rotary knob. 4
The operating display 3 shows the settings.
Activate / deactivate the remote controller
• Carry the step switch 1 in position
Turn right on rotary knob 4: remote controller is activated
Turn left on rotary knob 4: remote controller deactivated
If the remote controller active, the control lamp will glow on the
operating display
3
Display settings
• Carry the step switch 1 in position and adjust the
function with the rotary knob. 4 The display presents the
following information.
„A“ Display shows the welding current
„V“ Display shows the welding voltage
„A-V“ Display works in duplex operation and it shows the
welding current and the welding voltage alternate.
5.2
Hotstart settings for the welding current and the parameter
At first the height of the needed welding current is based upon the used electrode diameter. In
addition the material thickness of the base material, the material and the welding position have
essential influence on the needed current so that only approximate reference values will be
furnished on this position.
The following worths are the benchmark:
Electrodes- Ø (mm) 2,0 2,5 3,25 4,0 5,0
Current (A) 40-80 60-100 90-150 140-180 170-230
So that you obtain a good fusion penetration in the area of the initial weld, you can use the
hotstart function. During the hot start time, the welding current will be increased by a defined
percentage value over the value of the welding current. The accelerated fusing will be enabled
during the start phase therefore. The current drops to the value of the appointed welding
current after the expiration of the hotstart time. The hotstart current and hotstart time can be
changed, so you can ideal adjust the requirement.
Manual electrode welding operation
15
Adjust the hotstart
• Adjust the Hotstart current:
Carry the step switch 1 in position and adjust the
percentage value with the rotary knob 4
• Adjust the hotstart time:
Carry the step switch 1 in position and adjust the
hotstart time with the rotary knob 4
If you don´t want to use the hotstart function, you have to set the
value “0” on all parameter.
Adjust the welding current
• Lay the electrode holder down on an insulated surface and carry
the step switch 1 in position .
Attention: Welding voltage is applied to the sockets!
• Adjust the welding current I1 with the rotary knob 4.
The unit is now ready to weld.
5.3
Energy regulation with remote controller
The manual remote controller (art.-nr. 0130.0.1059) have available for the energy regulation as
accessories.
TIG welding
16
6. TIG (WIG) welding
Although the welding units of the MobiARC series primary to be destined for the manual
electrode welding operation, you can use it nevertheless for TIG welding.
Therefore you need a TIG hose package with integrated gas valve. The ignition happens as
contact ignition with minimal current, whereby the damages on the needlepoint will be avoided
as for as possible. The following settings for TIG welding are other than the given values from
the manual electrode welding operation.
Establish the readiness for operation
• Connect the hose package and the earth cable.
Plug the TIG hose package in the with „–“ marked socket,
plug the earth cable in the with „+“ marked socket. Lock the
bayonet lock.
Fixate the pole terminal of the ground cable at the workpiece. The
contact point must be cleared of paintworks, layers of fat and
oxide layers.
• Pressure reducer have to be plugged on the protective gas cylinder
(Argon 4.6), gas hose of the hose package have to be plugged on
the pressure reducer, gas cylinder valve have to be opened and the
needed protective gas value have to be adjusted.
Adjust the welding current
• Lay the electrode holder down on an insulated surface and carry
the step switch 1 in position .
Attention: Welding voltage is applied to the sockets!
• Adjust the welding current I1 with the rotary knob 4. You can
open the gas valve at their hose package.
The unit is now ready to weld.
5.2 TIG welding with remote controller
You have two options to use a remote controller. You can either use the manual remote
controller (art.-nr.
013.0.1059) or use the base remote controller for the energy regulation
(art-nr. 019.0.3000).
The remote controller will be plugged at the appropriate 10 pole socket on
the front. Please note that the remote controller must be activated.
Technical data
17
7. Technical data MobiARC 280 cel
Primary:
Voltage: 3 x 400 V
Frequency: 50/60 Hz
Cont. power (/MMA/TIG): 8.3 kVA / 5.5 kVA
Cont. current (MMA/TIG): 12 A / 8 A
Max. current (MMA/TIG): 21 A / 16 A
cos phi: 0.98
MMA/stick electrode operation:
Stick electrode: 1.5 - 6.0 mm (Cel suitable)
Open circuit voltage: 96 V
Welding voltage: 20.6 – 31.20 V
Welding current: 15 - 280 A
280 A (40 °C)
Duty cycle 35 %: (10 min.) 250 A (40 °C)
Duty cycle 60 %: (10 min.) 250 A (20° C) 210 A (40° C)
Duty cycle 100 %: 210 A (20° C) 170 A (40° C)
TIG operation:
Open circuit voltage: 96 V
Welding voltage: 10 – 21.2 V
Welding current: 5 - 280 A
280 A (40 °C)
Duty cycle 25 %: (10 min.) 250 A (40 °C)
Duty cycle 60 %: (10 min.) 250 A (20° C) 210 A (40° C)
Duty cycle 100 %: 210 A (20° C) 170 A (40° C)
Current source: inverter
Protection class: IP 23 Norm: EN 60974-1 "S" / CE
Isolation class: H Socket 50 mm²: earth lead cable
Cooling: AF Socket 50 mm²: electrode welding cable
Main switch: 3-phase Mains supply cable: 4 x 2.5 mm², 5 m long
Operation modes: MMA/stick welding, with plug schuko 400 V/16 A
TIG (DC) welding with Weight: 16 kg
lift arc ignition Dimensions L x W x H : 485 x 200 x 435 mm
Potentiometer: welding current Current source: inverter
LED: mains ON, welding ON
LED: temperature protection
Display: LED indication for
Remote control: electricity, time, voltage
power socket 10-pole
Idling cycle: optional
Primary:
Voltage: 3 x 400 V
Technical data
18
8. Technical Data MobiARC 280 cel ±
Primary:
Voltage: 3 x 400 V
Frequency: 50/60 Hz
Cont. power (/MMA/TIG): 8.3 kVA / 5.5 kVA
Cont. current (MMA/TIG): 12 A / 8 A
Max. current (MMA/TIG): 21 A / 16 A
cos phi: 0.98
MMA/stick electrode operation:
Stick electrode: 1.5 - 6.0 mm (Cel suitable)
Open circuit voltage: 96 V
Welding voltage: 20.6 – 31.20 V
Welding current: 15 - 280 A
280 A (40 °C)
Duty cycle 35 %: (10 min.) 250 A (40 °C)
Duty cycle 60 %: (10 min.) 250 A (20° C) 210 A (40° C)
Duty cycle 100 %: 210 A (20° C) 170 A (40° C)
TIG operation:
Open circuit voltage: 96 V
Welding voltage: 10 – 21.2 V
Welding current: 5 - 280 A
280 A (40 °C)
Duty cycle 25 %: (10 min.) 250 A (40 °C)
Duty cycle 60 %: (10 min.) 250 A (20° C) 210 A (40° C)
Duty cycle 100 %: 210 A (20° C) 170 A (40° C)
Protection class: IP 23 Current source: inverter
Isolation class: H Norm: EN 60974-1 "S" / CE
Cooling: AF Socket 50 mm²: earth lead cable
Main switch: 3-phase Socket 50 mm²: electrode welding cable
Operation modes: MMA/stick welding, Mains supply cable: 4 x 2.5 mm², 5 m long
TIG (DC) welding with with plug schuko 400 V/16 A
lift arc ignition Weight: 17 kg
Potentiometer: welding current Dimensions L x W x H : 485 x 200 x 435 mm
LED: mains ON, welding ON
LED: temperature protection
Display: LED indication for
Remote control: electricity, time, voltage
power socket 10-pole
Idling cycle: optional
Primary:
Voltage: 3 x 400 V
Frequency: 50/60 Hz
Cont. power (/MMA/TIG): 8.3 kVA / 5.5 kVA
Maintenance
19
9. Maintenance
The maintenance of the unit is consisted of regular cleaning and inspection. The frequency of
the process depends on the degree of utilisation and the workplace ratio.
W
arning!
Before start the cleaning and inspection:
• Wait the discharging time (about 3 minutes) of the electrolytic
capacitor.
• Disconnect the current supply through unplugging the mains plug.
Allow the unit cool down.
Cleaning:
• You have to use only degreasing agents which approriate for the electrical units and
devices.
- Screw off the cover,
- Suck dirt and dust dry of the unit.
- Wipe the components clean,
- Fit in and fasten in place the cover.
Inspection:
- Screw off the cover,
• Check the unit for,
- worned and defected wires,
- loosely connections.
- If necessary put in order.
• Check the torch hose package and torch connections for,
- defected positions.
- If necessary put in order.
Fit in and fasten in place the cover.
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