150v, 200, 270 and 340
MXL Torches
Form No: 0558007454 03 / 2007
Instruction Manual
Installation, Operation and Service
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of opera-
tion and safe practices for arc welding and cutting equipment, we urge you to read our booklet, "Precautions
and Safe Practices for Arc Welding, Cutting, and Gouging," Form 52-529. Do NOT permit untrained persons to
install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you
have read and fully understand these instructions. If you do not fully understand these instructions, contact
your supplier for further information. Be sure to read the Safety Precautions before installing or operating
this equipment.
Be sure this information reaches the operator.
You can get extra copies through Your supplier.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and
accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance
with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly
maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contami-
nated should be replaced immediately. Should such repair or replacement become necessary, the manu-
facturer recommends that a telephone or written request for service advice be made to the Authorized
Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manu-
facturer. The user of this equipment shall have the sole responsibility for any malfunction which results
from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the
manufacturer or a service facility designated by the manufacturer.
CAUTION
ENGLISH
-- 1 --
TOCe
1 DIRECTIVE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 SHIPMENT AND PACKAGING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 TECHNICAL DATA 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 OPERATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Fitting the liner 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Assembling the swan neck 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Fitting the central adaptor assembly to the equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Setting the level of shielding gas 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Checklist 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 Changing wire 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 MAINTENANCE 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Cable assembly 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Cleaning the wire feed 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Spiral liner / PTFE liner 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Cleaning the swan neck 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 FAULT--TRACING 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 DISASSEMBLY AND DISPOSAL 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 IN THE EVENT OF AN EMERGENCY 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 ORDERING OF SPARE PARTS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEAR PARTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS
4
5
17
19
21
23
23
23
24
24
1
2
3
4
5
6
7
24
24
25
26
27
25
25
26
29
4
DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, S--695 81 Laxå, Sweden, gives its unreserved guarantee that torch
MXL 150v, MXL 200, MXL 270, MXL 340 are constructed and tested and complies with standard
EN 60974--7, in accordance with the requirements of directive (2005/95/EEC).
--------------------------------------------------------------------------------------------------------------------------------------
Kent Eimbrodt
Global Director Equipment and Automation
ESAB AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 2007--03--08
5
SAFETY PRECAUTIONS
Safety Precautions
Safety - English
WARNING: These Safety Precautions are
for your protection. They summarize pre-
cautionary information from the references
listed in Additional Safety Information sec-
tion. Before performing any installation or operating
procedures, be sure to read and follow the safety
precautions listed below as well as all other manuals,
material safety data sheets, labels, etc. Failure to observe
Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield tted with the correct lter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operat-
ing or observing operations. Warn bystanders not
to watch the arc and not to expose themselves to
the rays of the electric-arc or hot metal.
3. Wear ameproof gauntlet type gloves, heavy long-
sleeve shirt, cuess trousers, high-topped shoes,
and a welding helmet or cap for hair protection, to
protect against arc rays and hot sparks or hot metal.
A ameproof apron may also be desirable as protec-
tion against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cus, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing.
5. Protect other personnel from arc rays and hot
sparks with a suitable non-ammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can y far.
Bystanders should also wear goggles over safety
glasses.
FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protec-
tive non-ammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in oors or wall openings and cause a hid-
den smoldering re or res on the oor below. Make
certain that such openings are protected from hot
sparks and metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might
produce ammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have re extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable re extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For ex-
ample, overloaded welding cable can overheat and
create a re hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later re. Use re watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA
02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is conned, or if there is
danger of falling.
6
SAFETY PRECAUTIONS
1. Be sure the power source frame (chassis) is con-
nected to the ground system of the input power.
2. Connect the workpiece to a good electrical
ground.
3. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
9. Turn o the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommenda-
tions. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric cur-
rent owing through any conduc-
tor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
2. Exposure to EMF may have other health eects which
are unknown.
3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connect the work cable to the workpiece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shield-
ing gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stain-
less steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
2. Do not operate near degreasing and spraying opera-
tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat ir-
ritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discom-
fort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specic ventilation recommendations.
7
SAFETY PRECAUTIONS
5. WARNING: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code
§25249.5 et seq.)
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and vio-
lently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and ttings in good
condition. Follow manufacturer's operating instruc-
tions for mounting regulator to a compressed gas
cylinder.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar-
riages, benches, walls, post, or racks. Never secure
cylinders to work tables or xtures where they may
become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and ames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jeerson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualied personnel perform the instal
-
lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equip-
ment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
8
SAFETY PRECAUTIONS
5. AWS C5.5 - "Recommended Practices for Gas Tung-
sten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Hand-
book.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANING OF SYMBOLS - As used
throughout this manual: Means Atten-
tion! Be Alert! Your safety is involved.
Means immediate hazards which,
if not avoided, will result in im-
mediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Means hazards which could result
in minor personal injury.
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17
1.0 INTRODUCTION
The MIG / MAG welding torches of this series are exclusively intended for shielded- arc welding using
inert gas (MIG) or active gas (MAG) for industrial and commercial use by suitably trained employees. The
torches are only available in manual versions.
SECTION 1 INTRODUCTION
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19
SECTION 2 SHIPMENT AND PACKAGING
2.0 SHIPMENT AND PACKAGING
The components are carefully checked and packaged however damage may occur during shipping.
Checking procedure on receipt of goods
Check that the shipment is correct by referring to the shipping note.
In case of damage
Check the package and components for damage (visual inspection).
In case of complaints
If the package and/or components have been damaged during shipment:
Contact the last carrier immediately.
Keep the packaging (for possible inspection by the carrier or supplier, or for returning the goods).
Storage in an enclosed space
Ambient temperature
for shipment and storage: - 25 °C to + 55 °C
Relative air humidity: up to 90% at a temperature of 20 °C
•
•
•
•
•
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21
SECTION 3 TECHNICAL DATA
3.0 TECHNICAL DATA
-- 4 --
bg13d2e
Storage in an enclosed space
Ambient temperature
-- for shipment and storage: -- 25 qC to + 55 qC
Relative air humidity: up to 90% at a temperature of 20 qC
5 TECHNICAL DATA
Welding torch MXL 150v MXL 200 MXL 270 MXL 340
Type of cooling Air Air Air Air
Permitted load
at 20% intermittence *
Carbon dioxide CO
2
150 A
Mixed gas Ar/CO
2
150 A
Permitted load
at 35% intermittence *
Carbon dioxide CO
2
120 A 200 A 270 A 340 A
Mixed gas Ar/CO
2
120 A 170 A 260 A 320 A
Recommended gas flow 8 -- 15 l/min 10--18 l/min 10--18 l/min 10--20 l/min
Max pressure 2.5 bar
Wire diameter 0.6--0.8 mm 0.6--1.0 mm 0.8--1.2 mm 0.8--1.2 mm
Weight
2.5 m hose package
1.1 kg -- -- --
3.0 m hose package -- 1.6 kg 2.2 kg 2.6 kg
4.0 m hose package -- 2.0 kg 2.6 kg 3.7 kg
Cable assembly
Standard length
2.5 m 3.0 m / 4.0 m 3.0 m / 4.0 m 3.0 m / 4.0 m
Standard--control cable 2--pole 2--pole 2--pole 2--pole
* The capacity my be reduced up to 30% when pulse welding.
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a
certain current without overheating.
General torch data with reference to IEC/EN 60 974--7
Type of voltage: DC voltage
Wire type: Standard round wire
Voltage measurement: Peak value of 113V
Connection protection
Machine side (EN 60 529):
IP3X
Shielding gas: CO
2
or Ar/CO
2
GB
22
SECTION 3 TECHNICAL DATA
23
SECTION 4 OPERATION
4.0 OPERATION
NOTE:
General safety regulations for the handling of the equipment can be found on
Page 5. Read them before you start using the equipment!
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user's responsibility to take adequate precautions.
MXL welding torches can be used in any welding position.
The torch switch in the MXL handle is suitable for 42 V, maximum 1 A.
4.1 FITTING THE LINER
Fit the correct wire quide liner for the application, as needed to suit the wire type and diameter, see
Subsection 5.3.
NOTE:
For information on how to install new liners and about correct assembly procedure, see
Maintenance subsection.
Spiral liner = for steel wire
Teon liner = for aluminum, copper, nickel and stainless steel wires
4.2 ASSEMBLING THE SWAN NECK
The following gures indicate how to assemble the dierent welding torch types.
-- 5 --
bg13d2e
6 OPERATION
General safety regulations for the handling of the equipment can be foun d on
page 2. Read them before you start using the equipment!
WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the user’s responsibility to take adequate precautions.
MXL welding torches can be used in any welding position.
The torch switch in the MXL handle is suitable for 42 V, maximum 1 A.
6.1 Fitting the liner
Fit the correct wire quide liner for the application, as needed to suit the wire typw and
diameter, see 7.3.
For information on how to install new liners and about correct assembly
procedure, see the chapter entitled “Maintenance”
Spiral liner = for steel wires
Teflon liner = for aluminium, copper, nickel and stainless steel wires
6.2 Assembling the swan neck
The following figures indicate how to assemble the different welding torch types.
MXL 150v
MXL 200
MXL 270
MXL 340
1. Gas nozzle 2. Contact tip 3. Nozzle spring 4. Tip adaptor 5. Gas diffusor
GB
24
SECTION 4 OPERATION
4.0 OPERATION CON'T.
4.3 FITTING THE CENTRAL ADAPTOR ASSEMBLY TO THE EQUIPMENT
Check that the wire guide liner is tted correctly.
Insert the central plug into the socket on the wire feed unit and secure it by tightening the adaptor
nut rmly.
4.4 SETTING THE LEVEL OF SHIELDING GAS
Set the quantity of gas required on the gas regulator. The type and quantity of gas to be used depends
on the welding task to be performed.
4.5 CHECKLIST
Check the cable assembly before connecting it to the wire feed unit to conrm the wire liner is suit-
able for the wire diameter and type.
Check the xed end consumable parts on the swan neck, whether the correct contact tip etc. is be-
ing used for the wire diameter and type.
4.6 CHANGING WIRE
When changing the wire, ensure that the end of the wire is deburred.
Insert the wire into the wire feeding unit in accordance with the operating instructions.
When inserting the wire, press the wire jog button on the wire feed unit.
1.
2.
•
•
•
•
•
25
SECTION 5 MAINTENANCE
5.0 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Welding torch
Cleaning and replacement of the welding torch's wear parts should take place at regular intervals in
order to achieve trouble-free wire feed. Blow the wire guide clean regularly and clean the contact
tip.
Before carrying out cleaning, servicing and repair work, the following shutdown procedure must be fol-
lowed.
Switch o the power supply.
Close o the gas supply.
Make sure that the power supply and gas remain turned o all the time while servicing the ma-
chine.
5.1 CA
BLE ASSEMBLY
Check that all the nuts are tight.
Replace the liner if it is worn or dirty.
Replace damaged, deformed or worn parts.
5.2 CLEANING THE WIRE FEED
Disconnect the torch cable assembly from the equipment and lay it out straight.
Unscrew the nut and pull out the wire guide liner. Remove other parts from the swan neck.
Blow compressed air through the wire conduit from both ends in order to remove wire shavings.
Insert the liner into the wire conduit and screw the nut back on.
NOTE:
New liners must be cut to the correct length.
Please follow the following tips and suggestions.
•
1.
2.
•
•
•
•
•
•
•
•
•
26
SECTION 5 MAINTENANCE
5.3 SPIRAL LINER / PTFE LINER
Unscrew all the ttings from the swan neck.
Unscrew the union nut on the central plug.
Remove the old liner, and then push the guide spiral liner through the hose as far as it will go. Make
sure the cable is stretched out more or less straight.
Tighten the union nut by hand.
Cut the overhang o the spiral at the swan neck and remove the guide spiral liner again.
For a smooth transition to the contact tip, grind the end of the spiral to an angle of approximately
40°. Debur the cutting edge.
Push the sharpened guide spiral liner through the hose to the holder nipple.
Screw the union nut into position and tighten it using the multiple spanner.
Screw the ttings back on again.
1.
2.
3.
4.
5.
6.
7.
8.
9.
5.0 MAINTENANCE CON'T.
-- 7 --
bg13d2e
7.2 Cleaning the wire feed
S Disconnect the torch cable assembly from the equipment and lay it out straight.
S Unscrew the nut and pull out the wire guide liner. Remove other parts from the
swan neck.
S Blow compressed air through the wire conduit from both ends in order to remove
wire shavings.
S Insert the liner into the wire conduit and screw the nut back on.
New liners must be cut to the correct length.
Please follow the following tips and suggestions:
7.3 Spiral liner / PTFE liner
1. Unscrew all the fittings from the swan neck.
2. Unscrew the union nut on the central plug.
3. Remove the old liner, and then push the guide spiral liner through the hose as
far as it will go.
Make sure the cable is stretched out more or less straight.
4. Tighten the union nut by hand.
5. Cut the overhang off the spiral at the swan neck and remove the guide spiral liner
again.
6. For a smooth transition to the contact tip, grind the end of the spiral to an angle
of approx. 40q. Deburr the cutting edge.
7. Push the sharpened guide spiral liner through the hose to the holder nipple.
8. Screw the union nut into position and tighten it using the multiple spanner.
9. Screw the fittings back on again.
GB
5.4 CLEANING THE SWAN NECK
Clean the inside of the gas nozzle regularly to remove welding spatter and spray with Prest-O-Lite
anti-spatter agent.
Check the consumables for visible damage and replace if necessary.
•
•
27
SECTION 6 FAULT TRACING
-- 8 --
bg13d2e
7.4 Cleaning the swan neck
S Clean the inside of the gas nozzle regularly to remove welding spatter and spray
with ESAB
anti--spatter agent.
S Check the consumables for visible damage and replace if necessary.
8 FAULT--TRACING
If the measures described below are not successful, please consult your dealer or
the manufacturer.
Please also read the operating instruc tions for the welding components, e.g. power
source and wire feed u nit.
Problem Cause Solution
Torch becomes too hot S Contact tip / Collets not tight
enough
S Current connections on the
torch side and to the work piece
are loose
S Check and tighten
S Check and tighten
No switch function S Control line interrupted / faulty S Check / Repair
Wire burnt back onto
the contact tip
S Wrong parameter setting
S Worn contact tip
S Check or correct the setting
S Replace
Irregular wire feed S Liner blocked
S Contact tip and wire diameter
do not match one another
S Wrong tension set on the wire
feed unit
S Blow through in both directions
S Replace contact tip
S Correct according to
manufacturer’s instructions
Short arc between the
gas nozzle and the
work piece
S Spatter bridge between the
contact tip and the gas nozzle
S Clean and spray the inside of
the gas nozzle
Variable arc S Contact tip does not match the
wire diameter, or the contact tip
is worn
S Incorrect welding parameters
set
S Liner worn
S Check and replace the contact
tip
S Correct the welding parameters
S Replace the wire guide
Porous welds S Large amount of spatter in the
gas nozzle
S Insufficient or total lack of gas
shield
S Draught is disturbing the
shielding gas
S Clean the gas nozzle
S Check contents of the gas
bottle and the pressure setting
S Shield welding area with
protective screens
GB
6.0 FAULT TRACING
If the measures described below are not successful, please consult your dealer or the manufacturer.
Please also read the operating instructions for the welding components, e.g. power source and wire
feed unit.
IN THE EVENT OF AN EMERGENCY, THE POWER SOURCE
MUST BE SWITCHED OFF IMMEDIATELY. FOR FURTHER
ACTION IN SUCH CIRCUMSTANCES, CONSULT THE
POWER SOURCE INSTRUCTION MANUAL.
CAUTION
28
SECTION 6 FAULT TRACING
29
SECTION 7 ORDERING OF SPARE PARTS
NOTE:
MXL 150v, MXL 200, MXL 270, MXL 340 is designed and tested in accordance with the in-
ternational and European standards IEC-/EN 60974-7. It is the obligation of the service
unit which has carried out the service or repair work to make sure that the product still
conforms to the said standard.
Spare parts may be ordered through your nearest Prest-O-Lite dealer, see the last page of this publica-
tion.
7.0 ORDERING OF SPARE PARTS
30
SECTION 7 ORDERING OF SPARE PARTS
7.0 ORDERING OF SPARE PARTS CON'T.
MXLt 150v, MXLt 200, MXLt 270, MXLt 340
Edition 070309
Ordering number
-- 10 --
bg13or
Ordering Number
Ordering no. Type Description Notes
0700 200 001 MXLt 150v Welding torch 2.5 m with fixed connection
0700 200 002 MXLt 200 Welding torch 3.0 m EURO Connection
0700 200 003 MXLt 200 Welding torch 4.0 m EURO Connection
0700 200 004 MXLt 270 Welding torch 3.0 m EURO Connection
0700 200 005 MXLt 270 Welding torch 4.0 m EURO Connection
0700 200 006 MXLt 340 Welding torch 3.0 m EURO Connection
0700 200 007 MXLt 340 Welding torch 4.0 m EURO Connection
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