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MERKLE INSQUARE W 300 DC Operation Manuals

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Operation Manual
TIG Welding Units model INSQUARE
W 300 /DC / W 420 /DC
W 300 AC/DC / W 420 AC/DC
W 600 AC/DC
MERKLE
Schweißanlagen-Technik GmbH
Industriestraße 3
D-89359 Kötz
Tel.: (08221) 915-0
Fax: (08221) 915-40
www.merkle.de

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   Summary of Contents for MERKLE INSQUARE W 300 DC

  • Page 1 Operation Manual TIG Welding Units model INSQUARE W 300 /DC / W 420 /DC W 300 AC/DC / W 420 AC/DC W 600 AC/DC MERKLE Schweißanlagen-Technik GmbH Industriestraße 3 D-89359 Kötz Tel.: (08221) 915-0 Fax: (08221) 915-40 www.merkle.de...
  • Page 3: Table Of Contents

    Content page Security indications before introduction Accident prevention regulations 2nd1 Safety instructions Duty cycle Instructions to avoid interferences due to electromagnetic influences EMC Technical Data: 5th1 TIG Welding Unit, model Insquare W 300 / 420 DC: 5th2 TIG Welding Unit, model Insquare W 300 / 420 AC-DC: 5th3 TIG Welding Unit, model Insquare W 600 AC-DC: Set Up...
  • Page 4 TIG hand welding torch - and spare parts 16th1 TIG Hand Welding Torch, Model TH 450 W, water cooled, 16th2 TIG Hand Welding Torch, Model TH 600 W, water cooled, Spare parts and wiring diagram 17th1 Spare part list TIG Insquare W 300/420 DC 17th2 Wiring diagram INS 300-420 DC 17th3...
  • Page 5: 1st Security Indications Before Introduction

    1st Security indications before introduction The welding unit is built according to 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. Instruct yourselves by trained staff from us or contact our appointed dealers.
  • Page 6 7) Protection when welding under increased electrical risks Welding rectifiers and welding power sources which can optionally be used for either direct or alternating current must be marked "S" in accordance with EN 60974-1 and BGI 534. Use insulating materials to protect you against contact with electrically conductive parts and damp floors.
  • Page 7: 3rd Duty Cycle

    3rd Duty cycle The duty cylce measurings have been carried out in accordance with EN 60974-1 / VDE 0544 part 1 (10 min working period). 60% duty cycle means: After a 6 min. welding period a 4 min welding pause must be respected. The electrical components are thermally protected against overheating.
  • Page 8 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.
  • Page 9: Technical Data

    Technical Data: 5th1 TIG Welding Unit, model Insquare W 300 / 420 DC: Insquare W 300 DC Insquare 420 DC Primary: Power supply: 3 x 400 V 3 x 400 V Frequency: 50 (60) Hz 50 (60) Hz cos phi: 0.95...
  • Page 10 Digital displays: 2 displays with pre-indication and hold function for current, voltage, time, frequency Timer functions: OFF, quick and slow pulsation, spot welding time Ignition: OFF, high frequency, lift arc Energy control: at the machine, at the torch, hand remote control, foot pedal Operation modes: 2-stroke, 4-stroke, 4-stroke with 2 currents, gas check,...
  • Page 11: 5th2 Tig Welding Unit, Model Insquare W 300 / 420 Ac-dc

    5th2 TIG Welding Unit, model Insquare W 300 / 420 AC-DC: Insquare W 300 AC-DC Insquare 420 AC-DC Primary: Power supply: 3 x 400 V 3 x 400 V Frequency: 50 (60) Hz 50 (60) Hz cos phi: 0.95 0.95 TIG DC operation: Open circuit voltage: 80 V...
  • Page 12 TIG AC "square arc", TIG AC "balanced TIG", MMA/stick electrode (-), MMA/stick electrode (+), MMA/stick electrode sinusodial, MMA/stick electrode square arc Selector 1: current 1, time 1, upslope and downslope time, start current, final current, ignition impulse, spot w. time, gas pre- and post-flow time Selector 2: current 2, time 2,...
  • Page 13 slope, current 1 + 2, final curr. Power source: IGBT inverter Ignition: HF generator or lift arc Norm: EN 60974-1 "S" / CE Torch connection: Euro connector with 5-pole plug Torch cooling: integrated water cooling system Socket 50 mm²: earth lead Socket 50 mm²: electode welding cable Mains supply cable:...
  • Page 14: 5th3 Tig Welding Unit, Model Insquare W 600 Ac-dc

    5th3 TIG Welding Unit, model Insquare W 600 AC-DC: Primary: Power supply: 3 x 400 V Frequency: 50 (60) Hz cos phi: 0.95 TIG DC operation: Open circuit voltage: 80 V Welding voltage: 10 - 34 V Welding current: 20-600 A Duty cycle 60 %: 600 A (10 min.) Duty cycle 100 %:...
  • Page 15 MMA/stick electrode sinusodial, MMA/stick electrode square arc Selector 1: current 1, time 1, upslope and downslope time, start current, final current, ignition impulse, spot w. time, gas pre- and post-flow time Selector 2: current 2, time 2, (for pulsation), AC balance, AC frequency, hotstart time a.
  • Page 16: Set Up

    A connection to ground (GND) must be done. 6th3 Welding Torch Attach the hose assembly to the Euro-connector with the flange nut. CAUTION: Employ original Merkle TIG-torches only ! Otherwise assurance claim is not accepted by us 6th4 Earth Lead (Work Cable) The earth lead must have an excellent ground.
  • Page 17: Tig-welding Unit, Model Insquare W 300 /420 / 600

    TIG-Welding Unit, model Insquare W 300 /420 / 600 The welding unit W 300 /420 / 600 are based on inverter technique and are suitable for TIG- welding in DC, AC and for MMA/stick electrode welding. Continuous setting of the welding current is up to 300 / 420 / 600A.
  • Page 18 Jumper location on pcb ME-TF-1.2 Insquare W 300, W 420, W 600...
  • Page 19 Reduced front panel JP 1 on pcb ME-TF-1.2 plugged I1/t1 PULS I2/t2 AC AC AC AC AC AC AC AC AC AC AC AC AC AC AC AC AC AC AC AC AC AC AC AC DC DC DC DC AC AC AC AC AC AC AC AC DC DC DC DC...
  • Page 20: Front Panel

    Front panel I1/t1 P U L S C A N P U L S S T A T U S I 2 / t 2 AC AC AC AC AC AC AC AC AC AC AC AC DC DC DC DC DC DC DC DC AC AC AC AC DC DC DC DC...
  • Page 21: Operation Of The Unit

    Operation of the Unit Control functions: INSQUARE W 300 / W 420 DC, INSQUARE W 300 / W420 AC/DC, INSQUARE W600 AC/DC 1: Main switch 2: Selector switch "welding mode" Stick electrode-DC, plus-pole on electrode* Stick electrode-DC, minus-pole on electrode TIG-DC, plus-pole on torch electrode* for extremly thin plates and metal foils, max.amps.
  • Page 22 Time 2 (for current in pulse slow) 0,01s…2,5s in DC 0,05s…2,5s in AC* Welding current 2 10%…100% of curr l Voltage indication; hold-function after the weld Time hotstart 0s..l,5s to assure ignition welding electrodes Current hotstart 10%..200% of curr l Arc Force 100%..250% of curr l increases the welding current in order...
  • Page 23 within 1 sec. the LED-indicator extinguishes U rms<48V and the LED-indicator "failure" enlights. By actuating the main switch pos switch OFF/ON, the generator is ready for work again. 14: Selector switch time functions Pulse slow (in DC and AC) During time 1 flows curr 1 (selector switch 3), during time 2 flows curr 2 (selector switch 4) ^ Pulse fast (only in DC) The fast pulse makes the DC-arc narrow.
  • Page 24 3.stroke: push down the torch trigger: the current slopes down on the value of the final current in the period selected by the timer. The final current continues flowing until the trigger is released. 4.stroke: release of the trigger: the final current is switched off and the gas postflow time starts. If during the welding process a second trigger is actuated, a switching over to current 2 is effected.
  • Page 25: Tig Welding

    Now push down the botton PROGRAMM-NR. 11 and select the desired program number by means of the rotary switch 6. The running program number is indicated on the lower LED-display 8. The upper LED-display 7 always indicates the availability of the selected program-no.
  • Page 26: 9th2 Preparing-values At Ac Welding

    Indicated values for butt welding joints and vertical welding positions are to be reduced by 5 up to 10% , for fillet and overlap joints increased by 10 % . By preheating of the workpiece with a material thickness of more than 6 mm up to 150 bis 200 °C the penetration is getting better.
  • Page 27: 10th1 Standard Values For The Metal Arc Welding

    If nevertheless should burn the electrode, the welding current is reduced to a minimum. An igniting of the electrode is prevented thus. Electrode high start (Hot Start): To secure ignition a higher start current is established for a short time. Anti Stick function: While sticking the electrode the current is reduced immediately onto the minimum value.
  • Page 28: Trouble Shooting

    12. Trouble Shooting Errors Causes / helps Green LED (mains) is off after switching ON - at least one phase missing the unit - mains connector wrongly connected - defective fuses F4, F5 on control transformator Waterpump runs longer than 10 s after - insufficient waterpressure or defective switching ON and the red LED (failure) water pressure switch...
  • Page 29: Cleaning

    13. Cleaning IMPORTANT: !!! Before opening the machine, disconnect it from mains !!! Open the side covers. Remove dust from all parts of the machine. Blow away the dust at the pcbs of the inverter withcompressed air –reduced pressure (appr. 0,5 – 1 bar). We recommend to clean the unit in regular periods. 14.
  • Page 30: Tig Hand Welding Torch - And Spare Parts

    16. TIG hand welding torch - and spare parts 16th1 TIG Hand Welding Torch, Model TH 450 W, water cooled, with Merkle TCG connector or with Euro connector Technical data: Cooling: water cooled DC range: 450 A, 60 % duty cycle...
  • Page 31 TIG Hand Welding Torch, Model TH 450 W, water cooled with Merkle TCG connector or with Euro connector...
  • Page 32 108.276 model TH 450 W, 8 m with Merkle TCG connector TIG hand welding torch 108.278 model TH 450 W, 8 m with Merkle TCG connector and potentiometer With Euro connector: TIG hand welding torch 104.402 model TH 450 W, 4 m...
  • Page 33 (delivered without ball joint) Kinking protection for TIG handle 107.998 O-ring 8 x 1.6 min 10 pcs 103.544 Merkle TCG connector plug 109.556 (water cooled) incl. rubber housing and 2 o-rings Gas hose 4.5 x 1.3 high flexible 107.972 Coupling nipple no.
  • Page 34 Description Part No._ 50.1 Power cable TH 450/250 W, 4m, 10qmm 104.378 for torches with Merkle TCG and Euro connector 50.2 Power cable TH 450/250 W, 8m, 10qmm 104.379 for torches with Merkle TCG and Euro connector 51.1 Control cable 3 x 0.5 LiYY min 50 m 107.646...
  • Page 35: 16th2 Tig Hand Welding Torch, Model Th 600 W, Water Cooled

    16th2 TIG Hand Welding Torch, Model TH 600 W, water cooled, with Euro connector Technical data: Cooling: water cooled DC range: 600 A, 60 % duty cycle AC range: 500 A, 60 % duty cycle 2.4 – 4.8 mm ∅ Electrodes: Weight: 360 g (without cable assembly)
  • Page 36 TIG Hand Welding Torch, Model TH 600 W, water cooled, with Euro connector...
  • Page 37 TIG Hand Welding Torch, Model TH 600 W, water cooled Pos. Description Part No._ TIG hand welding torch 104.410 model TH 600 W, 8 m with Euro connector TIG hand welding torch 104.416 model TH 600 W, 8 m with Euro connector and potentiometer Standard equipment: 4.0 mm, ceramic 13 Spare parts and consumables:...
  • Page 38 Pos. Description Part No._ pc board for TIG double button 107.992 switch (for torch with ball joint) Switch button (red) 107.994 for TIG torch with ball joint Handle TIG torch, right and left 107.988 side (delivered without ball joint) Kinking protection for TIG handle 107.998 48/49 Gas hose 4.5 x 1.3 high flexible 107.972...
  • Page 39: Spare Parts And Wiring Diagram

    17. Spare parts and wiring diagram 17th1 Spare part list TIG Insquare W 300/420 DC 02.04.2004 electr. description part no. line filter ME-NF400/2.5 102.279 pc -board ME-I-PG-1.1 003.0.0001 pc -board ME-I-PI-1.0 003.0.0002 pc -board Pc-board ME-I-SD-1.1B 003.0.0003 pc -board ME-I-RC-1.1 003.0.0004 LEM-converter HTA 400 S 010.0.1615...
  • Page 40: 17th2 Wiring Diagram Ins 300-420 Dc

    electr. description part no. NTC resistor 47 kΩ (prim. IGBT) 010.0.1933 selector (option automatic welding) 003.0.0900 main transformer with choke 020.1.1661 control transformer EI 120/73,7 950VA 003.0.0242 converter 020.1.1124 converter 020.1.1124 sec. rectifier-modul 001.0.0287 sec. rectifier-modul 001.0.0287 sec. rectifier-modul 001.0.0287 sec.
  • Page 45: 17th3 Spare Part List Tig Insquare W 300 Ac/dc

    17th3 Spare part list TIG Insquare W 300 AC/DC 02.04.2004 electr. Description part no. line filter ME-NF400/2.5 102.279 pc -board ME-I-PG-1.1 003.0.0001 pc -board ME-I-PI-1.0 003.0.0002 pc -board ME-I-SD-1.1B 003.0.0003 pc -board ME-I-WS-1.1 003.0.0105 pc -board ME-I-WE-1.1 003.0.0006 pc -board ME-I-WE-1.1 003.0.0006 pc -board ME-I-RC-1.1 003.0.0004...
  • Page 46: 17th4 Wiring Diagram Ins W 300 Ac/dc

    electr. Description part no. resistor 3,3 Ω-50 W 030.0.4581 resistor 3,3 Ω-50 W 030.0.4581 resistor 3,3 Ω-50 W 030.0.4581 resistor 3,3 Ω-50 W 030.0.4581 resistor 330 Ω-50 W -R10 030.0.4583 resistor 100 Ω-50 W -R11 030.0.4582 resistor 100 Ω-50 W -R12 030.0.4582 -R13...
  • Page 52: 17th5 Spare Part List Tig Insquare W 420 Ac/dc

    17th5 Spare part list TIG Insquare W 420 AC/DC 02.04.2004 electr. Description part no. line filter ME-NF400/2.5 102.279 pc -board ME-I-PG-1.1 003.0.0001 pc -board ME-I-PI-1.0 003.0.0002 pc -board ME-I-SD-1.1B 003.0.0003 pc -board ME-I-WS-1.1 003.0.0105 pc -board ME-I-WE-1.1 003.0.0006 pc -board ME-I-WE-1.1 003.0.0006 pc -board ME-I-RC-1.1 003.0.0004...
  • Page 53: 17th6 Wiring Diagram Ins W 420 Ac/dc

    electr. Description part no. resistor 3,3 Ω-50 W 030.0.4581 resistor 3,3 Ω-50 W 030.0.4581 resistor 3,3 Ω-50 W 030.0.4581 resistor 3,3 Ω-50 W 030.0.4581 resistor 330 Ω-50 W -R10 030.0.4583 resistor 100 Ω-50 W -R11 030.0.4582 resistor 100 Ω-50 W -R12 030.0.4582 -R13...
  • Page 59: 17th7 Spare Part List Tig Insquare W 600 Ac/dc

    17th7 Spare part list TIG Insquare W 600 AC/DC 02.04.2004 electr. Description part no. -A1m pc-board ME-I-PG-1.1 003.0.0001 -A1s pc -board ME-I-PG-1.1 003.0.0001 -A2m pc -board ME-I-PI-1.0 003.0.0002 -A2s pc -board ME-I-PI-1.0 003.0.0002 -A3m pc -board ME-I-SD-1.1B 003.0.0003 -A3s pc -board ME-I-SD-1.1B 003.0.0003 pc -board ME-I-WS6-1.0 003.0.0104...
  • Page 60 electr. Description part no. relais 48V (option: automatic welding) 010.0.1961 relais socket 010.0.1962 choke (ferrit) 103.023 -M1m fan 230 V-AC at the Inverter 001.0.1323 -M1s fan 230 V-AC at the Inverter 001.0.1323 -M2m fan 230 V-AC at the Inverter 001.0.1323 -M2s fan 230 V-AC at the Inverter 001.0.1323...
  • Page 61: 17th8 Wiring Diagram Ins W 600 Ac/dc

    electr. Description part no. -T4m converter 020.1.1124 -T4s converter 020.1.1124 converter 020.1.1124 -V1m/ sec. rectifier-modul 001.0.0287 V1s to V12m/ V12s -V13m prim. rectifier 001.0.0285 -V13s prim. rectifier 001.0.0285 -V14m thyristor modul 001.0.0286 -V14s thyristor modul 001.0.0287 -V15m prim. IGBT 001.0.0173 -V15s prim.
  • Page 71: Eu-conformity Attestation Ins 300-420

    The above mentionned unit complies with the following European Regulations: EU-Low Voltage Regulation 73/23/EWG EU-Electromagnetic Compatibility 89/336/EWG In case of any modifications, incorrect repairs not exclusively authorized by Merkle, this attestation looses its valdity. Applied norms EN 60974 - 1 / IEC 974 - 1 / VDE 0544 part 1...
  • Page 72: Eu-conformity Attestation Ins 600

    The above mentionned unit complies with the following European Regulations: EU-Low Voltage Regulation 73/23/EWG EU-Electromagnetic Compatibility 89/336/EWG In case of any modifications, incorrect repairs not exclusively authorized by Merkle, this attestation looses its valdity. Applied norms EN 60974 - 1 / IEC 974 - 1 / VDE 0544 part 1...
  • Page 73 Notes:...
  • Page 74 M E R K L E Schweissanlagen-Technik GmbH MERKLE Schweissanlagen-Technik GmbH Industriestrasse 3 D-89359 Koetz, Germany Tel.: ++49-8221-915-0 Fax: ++49-8221-915-40 www.merkle.de 2. Edition 2004 July 13th, 2004 Technical changes reserved...

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