MLC 30. Bruksanvisning Brugsanvisning Bruksanvisning Käyttöohjeet Instruction manual Betriebsanweisung

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1 MLC Bruksanvisning Brugsanvisning Bruksanvisning Käyttöohjeet Instruction manual Betriebsanweisung Manuel d instructions Gebruiksaanwijzing Instrucciones de uso Istruzioni per l uso Manual de instruções Ïäçãßåò ñþóåùò Valid from Serial NO 519 XXX -XXXX

2 SVENSKA... 3 DANSK... 9 NORSK SUOMI ENGLISH DEUTSCH FRANÇAIS NEDERLANDS ESPAÑOL ITALIANO PORTUGUÊS ÅËËÇÍÉÊÁ Rätt till ändring av specifikationer utan avisering förbehålles. Ret til ændring af specifikationer uden varsel forbeholdes. Rett til å endre spesifikasjoner uten varsel forbeholdes. Oikeudet muutoksiin pidätetään. Rights reserved to alter specifications without notice. Änderungen vorbehalten. Sous réserve de modifications sans avis préalable. Recht op wijzigingen zonder voorafgaande mededeling voorbehouden. Reservado el derecho de cambiar las especificaciones sin previo aviso. Ci riserviamo il diritto di variare le specifiche senza preavviso. Reservamo--nos o direito de alterar as especificações sem aviso prévio. Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ùñßò ðñïåéäïðïßçóç

3 ENGLISH 1 DIRECTIVE SAFETY INTRODUCTION Technical data TECHNICAL DESCRIPTION Wire feed unit MLC INSTALLATION OPERATION MAINTENANCE ORDERING OF SPARE PARTS DIAGRAM SPARE PARTS LIST TOCe

4 1 DIRECTIVE DECLARATION OF CONFORMITY Esab Welding Equipment AB, S Laxå, Sweden, declares that Wire feed unit MLC 30 from serial number 519 onwards, conforms to standard EN , in accordance with the requirements of directive (73/23/EEC) and appendix (93/68/EEC) and standard EN in accordance with the requirements of directive (89/336/EEC) and appendix (93/68/EEC) Laxå Paul Karlsson Managing Director Esab Welding Equipment AB LAXÅ SWEDEN Tel: Fax: SAFETY WARNING ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU- TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA. ELECTRIC SHOCK - Can kill S Install and earth the welding unit in accordance with applicable standards. S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing. S Insulate yourself from earth and the workpiece. S Ensure your working stance is safe. FUMES AND GASES - Can be dangerous to health S Keep your head out of the fumes. S Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and the general area. ARC RAYS - Can injure eyes and burn skin. S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing. S Protect bystanders with suitable screens or curtains. FIRE HAZARD S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby. NOISE - Excessive noise can damage hearing S Protect your ears. Use ear defenders or other hearing protection. S Warn bystanders of the risk. MALFUNCTION - Call for expert assistance in the event of malfunction. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS!

5 3 INTRODUCTION The MLC 30 is a component of the A9 semi--automatic series push--pull --system. This means that a motor driven wire feed unit pushes the wire through the welding hose to the gun, and from there the compressed air motor in the welding gun pulls the wire out to the contact tip. The push--pull system ensures smooth, problem--free wire feed, which is especially important when welding soft consumables such as aluminium and thin wires. It also permits the use of welding hoses up to 16 m in length. It simplifies the work of the welder considerably and extends his working radius, since the wire feed unit can also be separated from the power source. Besides the drive motor, the wire feed unit comprises a connecting block for the welding hose, brake hub for wire reels up to 300 mm in diameter, plus control devices, i.e. solenoid valve for shielding gas, compressed air valve with filter regulator and current relay. The wire feed unit can be placed in a variety of positions. If equipped with a counterbalance and/or turntable the MLC 30 can be made to swivel over the guide journal on the power source. It can be fitted with a suspension device and suspended over the work place. It can also be fitted with wheels (carriage) for free--standing use and easy positioning on the floor or work bench. MLC 30 is available in two versions for 42 V, 50/60 Hz or 115 V, 50/60 Hz. 3.1 Technical data Connection data Continuous A weighted noise pressure level 58 db Voltage 42 V, 50/60 Hz, 115 V, 50/60 Hz (special version) Power rating 85 VA Control cable Conductor, type RDO 6x1 mm 2 Gas connection Hose nipple for 6 mm hose Air connection Coupling för 1/4 hose Air pressure Max. 500 kpa (5 kg/cm 2 ) Welding current Max. 400 A at 60 % duty cycle Wire feed speed Max. 15 m/min. Adjusted at welding gun Wire diameter mm Inlet nozzle Outlet nozzle Brake hub intended for wire reel with: External diameter Hub diameter Hub length Dimensions Lxbxh Weight Bore 2,7 mm Bore 1,5 mm Outlet nozzle must be removed with 1,6 mm wire 300 mm 51.1 mm 100 mm 320x240x255 mm 10 kg

6 3.2 TECHNICAL DESCRIPTION The MLC s steel casing is divided vertically into two sections. One section, which is protected by a screwed panel, contains the electrical and pneumatic regulating equipment. The other section is covered at the top and side by a hinged panel. In the closed position the panel is secured to the bottom panel by a snap lock. This section contains the hub for the wire reel, wire feed mechanism with electric motor and connecting block for welding hose, shielding gas and compressed air, plus the gas valve. In very dirty or dusty locations a reel guard with cover can be fitted to the brake hub. This accessory is ordered separately. The bottom panel is fitted with a grommet to allow passage of the welding cable out of the power source. MLC 30 is fitted with a filter regulator. This drains automatically when the compressed air system is switched off. The pressure is permanently set at 500 kpa (5 kg/cm 2 ). 3.3 Wire feed unit MLC 30 The motor driven wire feed unit is mounted on the output shaft of the electric motor and comprises a driven feed roller and freewheeling pressure roller. The pressure roller, which consists of a simple ball bearing, is mounted on a camshaft, which runs in a needle bearing housed in the casing. Pressure is exerted on the wire by means of torque applied to the camshaft by an adjustable spring mechanism. The design of the wire feed unit insulates the welding wire from the outer casing. The inlet and outlet nozzles are made of hardened steel. When welding with j1.6 mm wire the outlet nozzle must be removed from the wire feed unit. On the front panel is a remote socket (M 26) to allow remote control of voltage. This requires a thyristor regulated power source, e.g. LAH 315/500 or LUA 400. IMPORTANT! To prevent the reel sliding off the hub: Lock the reel in place by turning the red knob as shown on the warning label attached next to the hub

7 4 INSTALLATION 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. The installation shall be executed by a professional. Connecting the welding hose 1. Open the side of the wire feed unit that contains the wire feed mechanism. Undo the locking screw on the connecting block. 2. Choose the appropriate inlet nozzle for the wire being used and push it securely into the welding hose. 3. Connect the welding hose to the wire feed unit and tighten the locking screw on the connecting block. 4. Remove the plastic cover from the gun housing, undo the locking screw and push in the other end of the welding hose. Then tighten the locking screw. 5. Check that the welding hose connections are correctly positioned and that the locking screws have been securely tightened. Refit the plastic cover. Connecting the welding current Connect the welding cable from the positive socket on the power supply to the current terminal on the connecting block. Connecting the compressed air Remove the panel, which is secured to the casing by four screws. Insert the air supply hose through the grommet in the opposite side of the casing (next to control cable) and connect the compressed air hose to the nipple on the filter regulator. Tighten the air hose coupling. NOTE! If the wire feed unit is suspended the filter regulator must be set in the vertical position. This prevents any water remaining in the compressed air system from reaching the welding gun and causing operating problems. Rotate the filter regulator anticlockwise so that it is directly opposite the hole in the casing intended for this purpose. Then tighten the filter regulator. Connecting the shielding gas Connect the shielding gas directly to the nipple on the solenoid valve

8 5 OPERATION Replacing the wire The wire conduit is made of plastic and can be damaged by sharp objects. Remove any burrs or sharp edges from the tip of the wire using a file, before feeding the new wire into the wire conduit. 1. Release the pressure roller springs. 2. Withdraw any remaining wire from the conduit. Remove the wire reel. 3. Fit the new wire reel. 4. Straighten out the first cm of the wire and file off any sharp edges from the tip of the wire. 5. Make sure the correct size inlet nozzle is fitted to the welding hose. 6. Guide the wire into the wire feed unit. Make sure it passes through the grooves in the feed rollers, into the outlet nozzle and then into the inlet nozzle of the welding hose. If welding with 1,6 mm wire the outlet nozzle must first be removed. 7. Re--tension the pressure roller springs. 8. Fit the correct contact tip to the welding gun. 9. Switch on the power source, press the gun trigger and allow the wire to advance through the welding hose and out of the contact tip. WARNING! Rotating parts can cause injury, take great care. 6 MAINTENANCE Cleaning When necessary clean the wire feed mechanism in the wire feed unit and the wire conduit in the welding hose using compressed air. Clean the grooves in the feed roller and pressure roller. You should also clean the inlet and outlet nozzles of the wire feed mechanism. Dismantle as follows: 1. Undo the screw on the connecting block using an Allen key, then remove the welding hose. 2. Undo the two stop screws that hold the inlet and outlet nozzles in place and remove them. 3. Refit the nozzles after cleaning. 7 ORDERING OF SPARE PARTS When ordering please state the machine model, serial number, part name and part number. This simplifies dispatch and ensures correct delivery