LORCH MX 350 EU User manual

LORCH
LORCH SchweiBtechnik GmbH
Im Anwander 24 - 26
D-71549 Auenwald
Telephone: [phone]
Fax: [phone]
Website: www.lorch.biz
Email: [email protected]
Operation Manual
MX 350 EU
909.1900.1-03

LORCH
Publisher LORCH SchweiBtechnik GmbH
Im Anwander 24 -26,
D-71549 Auenwald, Germany
Telephone: [phone]
Telefax: [phone]
Website:
E-mail: www.lorch.biz
[email protected]
Document number 909.1900.1-03
Issue date 16.10.2013
Copyright © 2012, LORCH SchweiBtechnik GmbH
This documentation including all its parts is protected by copyright. Any use or
modification outside the strict limits ofthe copyright law without the permission of
LORCH SchweiBtechnik GmbH is prohibited and liable to prosecution.
This particularly applies to reproductions, translations, microfilming and storage and
processing in electronic systems.
Technical changes Our machines are in a constant state offurther development, and the right is
reserved to make technical changes without notice.

Table of contents
1
2
Machine elements ...... . ..... . . 4
Explanati
on of symbols ..... .... 4
2.1 Meaning of the symbols in the operation
manual . . ... . .. . . ...... . . ..... . . . . . . . . .4
2.2 Meaning of the symbols on the machine ... . . .4
3 Safety precautions .. . . . . .. ... .. 5
4 Ambient conditions ............. 5
5 General regulation
of use . ..... . . 6
6 UW inspe ct i on ....... .. . .. .... 6
7 Unit protection . . . . ..... . . .. . . . . 6
8 Noise emission .. . ... . . . .... . . . 6
9 Electromagnetic co mp a tibility
(EMC) . .. ........ ..... . . ...... 6
10 Transport . . ........... . . . ... . . 6
11 Befor e start-up . ............ ... . 7
11. 1 Fasten transportation belt. ..... ..... . ..... .7
11.2 Fastening accessories bel t. . . ..... . . ....... 7
11.3 Electrode we lding process ... . . . . . . . . ...... 8
11.4 T IG welding process ... ....... ... .... .. ... 8
11.5 MIG welding process . . . . . . . ..... . ... . .... 9
11 .6 Connecting th e g ro und cable ...... . ... ..... 9
11 .7 Connecting the power supply ... ... ... ...... 9
12 Start-up ...................... 10
12 .1 Electrode welding process ... ............ .11
12.2 TIG welding
pr ocess............ ..... . .. .12
12 .3 MIG welding process (MIG/MAG} ...... . . ... 12
12.4 Calling up the seconda ry parameters ...... .. 13
12.5 Special functions . . . . . . . . . . ..... . . ... . . .14
13 Graphs . . .. .. . ..... .... . .... . 15
13.1 El ec trode ... .... ... ... • .... . . . . . . ... .. 15
13.2 TIG ... .. . ...... . . .. . .. .. .. . . . . . . . .... 15
13.3 MIG (MIX, C0
2) . • • •
•• . •• . .•.•.• . ••••••. 15
14 Messages. .... ... ...... . .. . . . 16
14.1 Status messages ........ . . . . . . . . . . . . . .. 16
14.2 Error messages . .. . .. . . .. . . . . . . . ... . ... 16
15 Welding bas ics . . .. ... .. . .. . . . 18
15.1 Stick electrode welding. ... • ... . . . . . ... ... 18
15.2 TIG welding .... . . . . . . . . .... . . . . . .. . . .. 18
16 Fundamentals of the MIG/MAG
welding pr ocess ...... . ....... 20
LORCH
16.1 Principle of the MIG/MAG welding process . . . 20
16.2 Arc types. . . . . . ........ . .. . . ...... . .. 20
17 Technical data ... .. ... .. . .. . . . 22
18 Maintenance and
repair . . ... . .. 24
19 Disposal .. .. ......... .. . ..... 24
20 Servic e ...... .. .... . . .. ... . .. 24
21 Declaration of conformity ... .... 24
22 Ersatzteilliste I spa re parts list I
Cm1coK ,a,eTan ei::t .... . ........ . 25
22 .1 MX 350 EU .. . .... . . . . . . . . . . . . ... ...... 25
23 Strom l aufplan I schematic I
CxeMaT HYeCKHH . .. . ... . ...... 28
23.1 MX 350 EU . . . . . . . . . . . . . . ... . . . . . . . . .28
23.2 Orahtvorscl1ubkoffer I wir e feeder/ 6 1101( no.Qa Y"1
npOB OJlO K l-1 MF-07 (EURO) .... ... . . . . . ... . 30
24 Anschlussbelegung I terminal
as
signm e nt I CxeMa KOHTaKToe
pa3beMa . . .... . . .. ... ... ... . 31
10.13 - 3 -

LORCH
1 Machine elements
Fig. 1: Machine elements
1 Mains cable holder
3 Handle (hoisting po i nt)
4 Operati ng field
6 Main swit ch
7 Remote co ntrol connecting socket
8 Connecting socket plug socket plus/minus (burn-
er/electrode holder/ground cable)
2.1
- 4 -
Meaning of the symbo ls in the opera-
tion manual
Danger to l ife and limb!
If the danger warnings are disregarded,
this can cause slight or severe injuries or
even death.
Danger of property damage!
Disregardi ng danger warnings can cause
damage to workpieces. too ls , and equip-
ment.
General note!
Indicates usef ul in format io n about the
product and eq uipment.
Explanation of symbo ls
9 Mains cab le
10 Connecting socket wire feed case 7 pin (versi on
E U)
CD
Some depicted or described accessories
are not included
in the scope of delivery.
Subject to change.
2.2 Meaning of the symbo ls on the
machine
&m Danger!
Read the user informati on in the operation
man
ual.
Disconnect the mains plug!
Pull out the mains plug before opening the
housing.
10.1 3

Ambient conditions LORCH
3 Safety precautions
~~~~~~~~~~~~~
Hazard-free working with the machine is
only possible if you read the operating and
safety instructions
co mpletely and strictly
observe them.
Please obtain practical training before us-
ing the machine for the fi rst time. Heed the
safety regulation (UVV").
Remove all solvents,degreasers. and other
flammable materials from the weld
in g area
before welding. Non-movable flammable
materials must be covered. Only weld
if the
ambient air contains no high concentra-
tions of dust, acid vapours, gases or flam-
mab le substances. Special care must be
taken during repair work on pipe systems
and tanks which contain or have contained
flammable liquids
or gases.
Never touch live parts inside or outside of
the housing. Never touch welding elec-
trod es or live we lding current parts in a
machine that is on.
Do
not expose the machine to rain; do not
clean with sprays
or steam jets.
Always use a protection shield when
we ld-
ing. Warn anyone in the wo rk area about
th e dangers or arc rays.
Plea
se use a suitable extraction system for
gases and cutti ng vapours.
Always
wear breathing apparatus when-
ever there is a risk of inhaling welding or
cutting fumes.
If the power cable is damaged or severed
while working, do nottouch the cable, but im-
media te ly pull out the mains plu g. Never use
a machi
ne ifthe mains cable is damaged.
Keep a fire extinguisher near the welding
area.
Check
the weldi ng area fo r fi re after we ldi ng
(see UW ' ).
Never t ry to disassemble the pressu re
reducer. Replace th e pressure re ducer if
faulty.
The machine must be transported
or set up
only on
fi rm , level surfaces.
T
he ma xi mum admissible angle of inclina-
tion fo r se tt ing up or transporting is 1o ·.
0 Service and re ;p air work may only be car ri ed out by a
trained electrician.
0 Ensure thatthe re is good directcontact for the ground
cable immed
iat ely beside the weld poin t. Donot pass
10. 13
the welding current through chains, ball bearings,
steel cabl
es, grounding conductors, etc., as it could
cause these to melt.
0 Secure yourselfand thewelding machine wh en work-
ing in elevated or inclined areas.
0 The m ac hine should be con nec ted only to a prope rl y
grounded mains suppl
y. (Three-phase four-wire sys-
tem with grounded neutral co nductor or single phase-
thr ee-wi re system with grounded neutral conductor)
socket and extension cable must have a functional
protective conductor.
D Wear protective clothing, l eat her gloves and leather
apron.
D Protect the we lding area with curtains or mob ile
screens.
D Do not use welding equipment to th aw outfrozen wa-
ter pipes or lines.
D In closed co ntainers, under cramped co nditions, and
in high electrical risk areas, only use machines with
the S sign.
0 When taking a break, switch off the machine and
close the valve on the gas
cy linder.
D Secure the gas cylinderwith a chain lo prevent it fall-
ing ove r.
D Disconnect the mains plug from the mains before
changing the place
of installa ti on or making re pairs
to the machine.
*) Only appli ca ble for German y. Can be or dered from
Carl Heymanns- Ve rlag, Luxemburger Sir. 449, 50939
Koln.
Please heed the safety re gulati ons which apply to your
country. Subject
to change.
4 Ambient conditions
Temperature range of ambient air:
in operation: -20 °C .. .+40 °c (-4 °F .. .+104 °F)
transport and storage: -25 •c .. .+55 •c(-13 "F .. . +131 "F)
Relative humidity:
up to so %at 40 •c (1 04 "F)
up to 90 %at 20 "C (68 "F)
~
Operation, storage and transport may only
be carries out within the ranges indicated!
Use outside of this range is considered not
used with its intended purpose. The manu-
facturer is not liable for damages cause by
misuse.
Am bient air must be free of dust, acids, corrosive gases
or other damag
in g substances!
-5 -

LORCH
5 General regulation of use
This machine is intended for use in the commercial and
industrial sector. It is portable and is suitab
le for opera-
tion on the mains supply or also on a power generator.
D The machine is intended for DC electrode welding of
-una ll oyed steels, low and high-alloy steels,
-
ni ckel and its alloys,
D Together with a T IG welding tor ch . the machine is
suitable for TIG we lding with direct current of
-unalloyed st ee ls, low and high-alloy steels,
-copper and its alloys,
- nickel and its alloys,
-special metals like titani
um , zirconium and tanta-
lum.
D Together with a wi re feed case, the machine is suit-
able for MIG welding with
-solid wire
(M IG/MAG),
flux-cored wire.
6 UW inspection
Operators of commercially-operated welding systems
are obliged to have regular safety inspections
of t he
equipment carried out in accordance with EN 60974-4.
Lorch recommends inspections al 12 month intervals.
A safety i
ns pection must also be car ri ed out if mod ifica-
tions or repairs have been made to the system.
G Improper
UW inspections can destroy the
system. For more information on UVV
in -
spections
of welding systems, please con-
tact your authorised Lorch service centre.
7 Unit protection
This machine is protected electronically against over-
loading. Do not use fuses of higher amperage than print-
ed on the identification plate.
8 Noise emissi on
The noise level of the unit is less than 70 dB(A}, meas-
ur
ed under standard load in accordance with EN 60974-
1 in the maximum wo rking poin t.
- 6 -
Trans port
9 Electromagnetic compatibility
(EMC)
This product is manufactured in conformance with the
current EMC standard. Please note the followin
g:
D Due to their high power consumption, weldi ng ma -
chines can cause problems in t
he public power grid.
The mai
ns connection is therefore subject to requi re-
ments with regard to the maximum permissible sys-
tem impedance. The maximum permissible system
impedance (Zmax)
of the interface to the power grid
(mains
con nection) is in dica ted in the tec hn ical data.
If in doubt, please contact your power grid operator.
D The machine is intended forwe ld ing in both commer-
cial and industrial applications (C ISPR 11 cl ass A).
Use in other surroundings (for example in residential
areas)
may disturb otherelectronic devices.
D Electromagnetic problems during start-up can arise
i
n:
-Mains cables, control cables, signal and telecom-
municat io n lines near the weldi ng or cutting area
-TV/radio transmitters/receivers
-Computers and other control devices
- Protection equipment such as alarm systems
-Pacemakers and hearing ai
ds
-Measurement and calibration devices
-Equipment with too little protection against inter-
ference
If other equipment is disturbed, it may be necessary to
provide additional shie
ld in g.
D The affected area may go beyond the boundaries of
the property concerned. This depends on the layout
of the bu ildi ng , and the other activities that may be
going on the re .
Please u
se the mac hi ne in compliance with the manu-
facturer's instructions. The operator of the equipment is
responsible for the installation and use
of the machine.
Furthe
rm ore, the owner is re sponsible (if necessary w it h
technical assistance from the manufacturer) for eliminat-
i ng the interference caused by e le ctromagnetic fiel ds .
10 Transport
For tran spo rt usi ng mec hanical l iftin g
gear (e.g. cranes etc.) o
nl y the handle
may be us ed as the hoi s ting p oin t. Use
suitable loa d- bear in g e qu ipment. Do
no t us e a for k- l ift 1r uck or s im ilar de-
vice
to li ft the mach ine by its housing.
The c
ar rying st rap is exc lu sive ly for the
transpo rt by a pe rson .
10. 13

Before start-up LORCH
11 Before start-up
---------------------------------~~~---------------~-----------------------------
11 .1 Fasten transportation belt
2
Fig. 2: Transporta tion belt
2 Ca rry ing belt
12 Pl as tic sli der
13 Velcro fastener
11 .2 Fastening accessories be lt
r1 _ _ ~
I L· ' ~~
, / I / 1
I ~/
' _, I
Fig. 3: Accessories belt
5 Accessor ie s be lt with fastener
12 Plastic slider
14 Closure
10.13
13
~ Thread the transportation be lt into the welding ma-
chine and plastic slides. See sequence of the num-
bering in
th e picture.
14
~ Thread the accesso ri es belt into the handle and plas-
tic slides. See sequence
of the numbering in the pi c-
ture.
~ Plug the belt fasteners together.
- 7 -

LORCH
11.3 Electrode welding process
Connecting the electrode welding cable
:> Connect the electrode welding cable to the minus
or plus socket 8 and secure the cable by rotating it
clockwise.
The polarity of the electrode depends on
the type of electrode and the welding pro-
cess. Please f ollow the manufactu r er's in-
structions on the electrode packaging for
this purpose.
11.4 TIG welding process
For TIG welding you req ui re a TIG valve
torch (Type L
TV2600) for this device
Installing electrodes
21 20
:> Unscrew the clamping cap 17.
:> Remove the electrode 16 from the collet 18.
:> Gri nd the end of the electrode 16.
:> Slide the electrode 16 into the collet 18 .
:> Insert the electrode 16 into the tor ch and firmly tight-
en the clamping cap 17 .
Do notdismantle the collet body 20 and the
gas nozzle 21.
When converting the torch to a different
electrode diamet er , please pay attention to
the following.
0 The collet 18, collet body 20 and electrode 16 must
have the same diameter.
0 The gas nozzle 21 must be matched to the electrode
diameter.
Connecting the TIG torch
:> Connect the TIG torch to the minus 8 connection
socket and secure it by turning it clockwi
se.
- 8 -
Before start-up
Connecting the inert gas cylinder
23
28'\<
I
Fig. 4: Gas connection
:> Place the inert gas cylinder 28 in a suitable location
and secure to prevent it from falling over.
D The cylindercan be secu red using a wall bracket or
cylinder troll
ey .
:> Briefly open the gas cylinder valve 27 several times
in order to blow out any dirt particles that are presen t.
:> Connect the pressure reducer 22 to the inert gas cyl-
inder 28.
:> Screw the inert gas hose 24 to pressure reducer 22
and open the gas cylinder valve 27.
Setting the inert gas quantity
:> Open the valve 19 on the TIG welding torch.
./ Inert gas flows out.
./ The flow met er 23 indicates the gas quantity, and
the content pressure gauge 26 indicates the cylinder
content.
:> Close the valve 19on the TIG welding torch when the
torch is not being used
in order to prevent unneces-
sary use of gas.
10.13

Before start-up
11.5 MIG welding process
71
A wire feed case (optional) is required for
MIG welding.
The operations required may differ de-
pending on the version and the configura-
tion
of the wire feed case!
Please observe the wire feed case operat-
ing manual!
Current source
74
Ground cable
LORCH
:> Connect the welding cable 73 on the wire feed case
to the connecting plug plus 8
or, in special cases, mi-
nus 8 on the power source.
:> Connect the control cable of the wire feed case 72
to the wire feed case connecting socket 1
Oon the
power source. (only on lnt case type)
:> Equipping the wire feed case. (See wire feed case
operating instructions)
77 MIG/MAG torch
72
Control cable (only on lnt case
75
Wire feed case
type)
76
Ground cable (only on lnt case
73
Welding cable type)
Fig. 5: MIG welding connection diagram
11.6 Connecting the ground cable
:> Connect the ground cable to the free minus orplus 8
socket and secure the cable by rotating it clockwise.
Fastening the ground clamp
~~~~~~~~~-
~!>""T----------------,,...-
Fig. 6: Attaching the groundclamp -Correct!
:> Fasten the grounding clamp in the immediate vicinity
of the welding area, so that the welding current can-
not seek its own return path across machine parts,
ball bearings or electric circuitry.
:> Connect the ground clamp firmly to the welding
bench or the workpiece.
10.13
Fig. 7: Attachingthe ground clamp -Wrong!
a Do not place the ground clamp on the welding ma-
chine or the gas cylinder; otherwise the welding cur-
rent will be carried via the protective conductors and
it will destroy these.
11.7 Connecting the powersupply
The machine is suitable for operation on the mains sup-
ply or on a current generator.
:> Plug the mains plug into the appropriate socket.
•••
·I
J.
..
The mains voltage and tolerance as well
as the fuse protection must correspond to
the technical specifications (see Technical
Specifications).
-9-

LORCH
12 Start-up
51 ~--= ~~ :=;;---__,,
50 ~ ~======:=::-~
49 ~,......,...=: ~~f k ,
Start-up
38 39 40 41 42 43
~
46
+ -
45
Fig. 8: Control penel MX 350
30
The Fault LED ~ ights up continuously, and the 38
The Synergy LED light sup if the Synergy function
fault co de isdisplayed in the 7 segment display is selected.
35.
39
The MIX LED lights up if MIG we lding oper at ing
31
The Remote control LED lights up when a remote mode with mixed gas is selected.
control is connected.
40 The C0
2 LED lights up
if MIG welding operating
Control knob 48 specifies the maximum value for mode with
C0
2 is selected.
the control range
of the remote control. If 1 OOA
41
The TIG LED lights up ifTIG operating mode is
has been set,
for example, 1 OA -1 OOA can be
called up using the remote control. selected.
Lights up when wire feed case (case type ln t) is
42 Electrode LED
connected lights up if Electrode operating mode is selected.
32 LEDVRD
43 Electrode CEL LED
lights up continuously with active VRD function lights up with operating
mode Electrode CEL
(reduction in idle running voltage) flashes if the sel
ec ted (Electrodes w ith cellulose-containing
output voltage exceeds the value pe rm itted by encapsulation, suitable for vertical downward
the standard (e.g. in welding mode or
if operating welding)
mode MSG welding LED 39, 40 selected) flashes ifgouging operating
mode selected.
33
The Seconds LED lights up when a value is dis-
44 welding process selector switch
played in the 7 segment display 35 in
sec . serves for selecting the TIG operating mode,
34 The % LED lights up when a value is displayed in MIG welding with mixing gas
the 7 segment display
35 in percent. MIG welding with
C0
2•
MMA or CEL electrode.
35 7-Segment-Display
If you hold the button down f or longer than 2
indicates the selected power level,
we ld voltage sees
., if the MIG (MIX/CO,) operating mode has
or wire feed speed. been selected, the Synergy operating mode is
If the secondary parameters are activated, the switched
on (LED Syner gy 38 lights up).
code and the set value are shown alternately.
If you hold the button down for longer than 2
36
Welding vo lta ge LED lights up when the welding sees., ifthe Electrode (MMA/CEL) oper at ing
voltage is displayed in the 7 segment display 35 mode has been selected,
the gouging opera!-
in volts. ing mode is switched on (LED Electrode CEL 43
37
The Welding current LED li ghts up when the flashes).
welding current is displayed in the 7 segment
45 Polarity indication
display 35 in amps.
46
Polarity indication
-10 · 10.13

Start-up
47 Selection button 2 cyc le/4 cyc le/cr ate r filling /gas
t est se rv es fo r se lec tion of 2 cycle, 4 cycle and
cra ter filling.
If the button is pushed for longer th an 2 sees., the
gas test
is started for approx. 30 sees.
48 The menu I wel ding curre nt control knob is used
for :
• The se lection of welding current, wel ding voltage
and the wire fe ed rate (press).
• The se tting of welding current, welding voltage
and the wire feed ra te (turn).
• Calling up the secondary parameters (press for
2 sees.)
• se l ect ing the se co ndary parameters (rotate).
• selecting the secondary parameters (press).
• setting the secondary parameters (rotate).
49 The Crat er fi lling LEDlights up if the Cr ater filling
fu nc tion is sel ected
50 LED 2-stroke lights up if you se le ct the 2-stroke
mode .
51 LED 4-stro ke lights up if you se l ec t the 4-stroke
mode .
12.1 El ectro de welding process
~~~~~~ ~~
Switch on the system
:> Switch on the sys tem at the ma in switch 6.
:> Keep pressing button 44 until the desired electrode
operating fun
ct ion is selected.
./ The e le ctrode MMA or CEL (LED 42 or 43) li ghts u p.
:> Use control kno b 48 to set the desired welding cur-
rent.
Electrode 0 [mm] Recommended current
In·
tenslty [A]
1.5 20 .. .40
2.0 35.
.. 60
2.5 45...100
3.2 75...140
4.0
13 0. .. 190
5.0 180
... 280
6.0 230
... 370
80
290...420
Tab. 1: Electrode diameter-Electrode
CD
Please follow the electrode manufacturer's
instructions
Electrode welding cur- Range Factory set-
rent
ting
Welding current 11 10 to 350A 100
Tab . 2: Electrode welding current
LORCH
Arc ignition
:> Briefly touch the wo rkpiece at the po int to be welded
us ing the electrode and li ft the electrode a little.
./ The arc burns between t he workpiece and the elec-
trode.
Hotstart
0 Ignition performance is improve d by in creasing t he
welding current (Hotstart).
:> Press the ope rating button 48 for 2 sees. to call up
the s ec ondary parameters.
:> Se l ec t the secondaryparameter Hotstart (Code "ISt")
by rotating the control kno b 48.
:> Confirm the secondary par am eter by pressing the
con trol knob 48.
:> Set the des ired value by rotating the con trol knob 48 .
:> Confirm t he setting by pressing the control knob 48.
:> Repeat the operations for setting the Hotstart ti me
'' tSt " secondary paramet er .
:> Exit the secondary parameters by pushing the oper-
ating button
48 for 2 sees., or by pressing the selec-
tion button 44.
Arc dynamics ( Arc Force)
0 The electro de is prevent ed from burning in in the
weld pool by means of a br ief current increase with
a short arc.
:> Press the operating button 48 fo r 2 sees. to call up
the secondary paramet
ers .
:i Select the Arc dy namics secondary parameter (Code
"dAF") by turning the control kn
ob 48.
:> Confirm the sec ondary parameter by pressing the
control knob 48 .
:> Set the des ir ed value by r ota ting t he control knob 48.
:> Confirm t he setting by press in g the control knob 48 .
:> Ex it the secondary paramet ers by pu sh ing the ope r-
ating button 48 for 2 sees
.. or by pressing t he selec-
ti on button 44.
10.13 -11 -

LORCH
12.2 TIG welding proces ~
Switch on the system
:> Switch on the system at the main switch 6.
:> Keep pressing button 44 until the desired MIG oper-
ating function is selected.
./ The TIG symbol (LED 41) lights up.
:> Use control knob 48 to set the desired welding cur-
rent.
TIG welding current Range
Factory
setting
Welding current 11
10 to 350A 100
Tab. 3: TIG welding current
Arc ignitio n
:> Open the valve 19 on the TIG welding torch.
CD
(
~
( p
'//////////////
'/// /// // //////
:> <D Briefly touch the workpiece with the tip of the elec-
trode at the point to be welded.
:> @ Lift the electrode a littl e.
./ The arc burns between the workpiece and the elec-
trode.
Upslope
O Ashort-circuit current of60A is used fo r igniting during
the TIG welding proc
ess. The upslope takes place with
115
Ns unt il the set welding current is reached.
Guidelinevalues for the current intensity and
the gas quantity
Tungsten electrode Current in- Gasquantity
diameter[mm] tensity [A] [Vmin]
1.0 3...40 4
1.6 15 ... 130 5
.. .6
2.0 45.
.. 180 5
.. .8
2.4 70
.. .240 6...10
3.2 140. .. 3 20
6 ... 12
4.0 220...450 6.
.. 14
-12 -
Start-up
12.3 MIG welding process (MIG/MAG} __
Switch on the system
:> Switch on the system at the main switch 6.
Selectingthe welding process
:> Keep pressing button 44 until the desired MIX or C0
2
operating function is selected.
./ The MIX or C0
2 symbol (LED
39 or 40) lights up.
Selecting th e wire feed case
CD
The type of connected wire feed case can
be selected at the welding unit.
0 If you are using a wire feed case with its own control
system you must set the case type lo external (EXI).
O If you a
re using a wire feed case without its own con-
trol system (with 6 or 7 pole connection plug) you
mustset the case type
to inte rn al (lnt).
:> Press the operating button 48 for 2 sees. to call up
the secondary parameters.
:> Select the case type secondary parameter (Code
"Fdt") by tu rn ing the control knob 48.
./ The parameter code and the correspon ding setting are
displayed alternately in the 7-Seg ment disp l ay 35 .
:> Confi rm the secondary parame t er by pressing the
control knob 48.
:> Set the desired case type by rot ating the control knob
48.
./ "lnt" or" EXt" is di splayed in t he 7segme nt dis p lay 35.
:> Confirm the setting by pressing the control knob 48 .
:> Exit the secondary parameters by pushing the oper-
ating button 48 for 2 sees
., or by pressing the selec-
tion button 44.
Operating mode EXtcase type
O Only the 2 cycle operating mode is possible in the
case type
E.Xt operating mode.
:> Set the welding voltage by rotating the control kn ob
48 .
:> Press the operating button 48 to display the welding
current.
O The welding current is only displayed during welding.
Operating mode lnt case type
:> Keep pushing the button 47 until the desired operat-
ing mode 2 cycle or 4 cycle an
d/or crater filling func-
tion is selected.
./ The LEDs 50 or 51 and/or49 light up.
:> Set the desired welding vol tage by rotating the knob
on the feed case.
:> Set the desired wire feed speed by rotating the knob
on the feed case.
10.13

Start-up
O Press the operating button 48 to switch between the
display of we lding voltage, we lding current and wire
feed speed.
./ The rel eva nt parameter value is d is played in the 7 seg-
ment display 35.
0 The we lding current is only displayed during welding.
Synergy
~ Press the selector button 44 for 2 sec. with the oper-
ating mode
MIG selected.
./' The Synergy
38 LED lights up.
CD
The set wi re diameter is displayed fo r ap-
prox. 5 sees. after switching on or selecting
the Synergy operating mode .
:> Select the wi re diameter parameter as follows
- Press the opera ti ng button 48 , whilst the wi re di-
ameter "d" is displayed in the 7 segment display.
(immediately after switching on or selecting the
Synergy operating mode)
-or select the secondary para
meter wire diam-
eter during subsequent operation (see "13.3 MIG
(MIX,
C02)" on Page 15)
:> Set the wi re diameter by rotating the cont ro l knob 48.
:> Confirm the setting by pressing the control knob 48.
:> If necessary, press the cont ro l knob48 for2 sees., or the
sele
ct ion button 44 to exit the secondary parameters.
:> Set the desired welding voltage by rotating the kn ob
on the feed case.
:> Set the wire feed rate on the rotary knob on the feed
case to
the m id dle position (0).
D In th e operating mode Synergy, the wire feed rate is
automati ca lly matched to the set we lding voltage.
:> Correct the wire feed rate, if necessary, on the feed
case by
tu rning to"+ " or"-" .
12.4 Calling up the secondary parameters
:> Press the operating button 48 for 2 sees. to call up
the secondary parameters.
:> Setthe desired secondary parameter by rotating the
control k
nob 48 .
./ The parame ter code and the corresponding setting are
displayed alternately in the 7- Segment display 3 5.
:> Confirm the secondary parameter by pressing the
control knob
48 .
:> The setting ea n be adjusted by rota ti ng the control
knob 48.
:> Confirm the setting by pressing the control knob 48.
:> The previous or next secondary pa ra met er is dis-
played by rotating the control knob 48.
D Different secondary parameters are available de-
pending on
the selected operating mode and func-
tion.
:> Press the control knob 48 for 2 sees., or the selection
bulton 44 to ex:it the secondary parame
te rs.
10.13
LORCH
Cl) Mode
::J Cl)
iii
en
~
c
ea
Cl>
>
ea
Cl>
::J
..
e
Parameter
'8
"E
c
en (!) c ea
0
Cll
c
~
i=
;;;
:::!:
"C
=
c 0 (!)
Cll G>
iii
-
"'
i i
"'
Start current ItSl
l: I
50 % 5
.. .200 % x
Start current tim e
fTSlB
0.1 s
O.O to
x
2 0s
Hots ta rt
LJjSLt_
1 25% 5 ... 200 % x
Hotstart time
~TSlf
1. 0 s O.Oto x
20 s
Arc dynamics
ld lA1F 100 % 0...200 % x
The we ld ing current increases automatically as the weld-
ing voltage is reduced. The arc dynamic indicates the ratio
between the weld
in g current and the automatic increase.
Arc end detection
RlEJdJ
100% 0...200 % x x
Yo urwelding machine switches the welding currento ff al
a certain arc length. (We ld end detection).The maxim um
length ofthe arc can be adapted using th e "AEd" param-
eter.
Inductor effect Ill
nd
I 100% 0. .. 200 % x x
Time bum back
!:b ib 100 % 1..
.2 00 % x x
Crater fi lling energy 1
i(if
50 % 0 .. . 10 0 % x
Crater filling voltage UJll 20V
10 to 40 x
v
C ra terfilli ng feed
tf_iE
5 0. .. 18 x
ra te m/min m/min
Crater filling lime
It Flt 1 s 0
to 10 s x x
(on ly with 2 cycle)
Case
ty pe (feeder f
ldlf
lnt ln t... EXI x x
type)
Cre ep in speed
_C ISIP2 2...18 x x
mlm in m
/m in
Wire diameter di
I ~~
0.8. .. 1 .2
mm
x
Tab. 4: Secondaryparameters
D The factory setting values a re op timised thanks to
automatic parameters.
You can use these factory settings unchanged for
most
we lding jobs.
- 13 .

LORCH
12.5 Special functions
Gouging
Cl Gouging is used for working out the roots or faulty
points and serves for preparing the weld seam.
Cl A special torch is required for gouging that has car-
bon electrodes and compressed air connection.
:> Keep pressing button 44 until the desired electrode
operating function (MMA or CEL) is selected.
./ The electrode MMAor CEL (LED 42 or43) lights up.
:> Press and hold the electrode button 44 for at least 2
seconds.
./ The Electrode CEL LED 43 flashes.
:> Set the desired current by rotating the control knob
48.
Master reset
CD
Warning! All personal settings will be
lost
All welding and secondary parameters are
reset to theirfactory settings (master reset
function).
:> Press buttons 44 and 47 simultaneously for at least
3 seconds.
./ The 7 segment display and the control panel indica-
tors light up briefly as confirmation.
Switching the Function lock on I off
:> Press the control knob 48 and the button 44 simulta-
neously for at least 3 seconds.
./
0
--
11
is briefly displayed in the 7 segment display 35
as confirmation.
./ All buttons on the control knob are blocked. If it is
operated,"--" is displayed.
Cl The control knob 48 and button 44 must be pressed
again for at least 3 seconds
in order to disable the
function lock.
-14-
The function lock setting is saved! If the
machine is switched off with the function
lock activated, the control panel is still
blocked when the machine is switched
back on.
Start-up
10.13

Graphs
13
Graphs
13.1 Electrode
I Current
11 Welding current
ISt Hotstart
t Time
tSt
Hotstart time
13.2 TIG
I Current
11 Welding current
ISt Start current
Iz Ignition current
t Time
tlu Upslope
tSt Start current time
13.3 MIG (MIX,
C0
2)
tbb
Tim e burn back
CF
Crater filling energy
I Current
11
Welding current
IC FU Current (crater filling vo ltage}
t Time
tCFt Cra ter filling time
v Speed
vCFF Speed craterfi ll ing feed rate
vCSP Creep in speed
t I
;
I S!
'
!S t
Fig. 9: Electrode currentrouting diagram
t
I
I
!lz
IS!
I ' :
l ' '
tlu :
'
tSt
I
'
,• ~ : ·
~ ·
'
'
Fig. 10: TIG current routingdiagram
t
I
(A)
11
!I
(mfmin)
vCS P
'
11
LORCH
11
ICFU
!CF
t -+
t-+
ICFt i I-+
:( s)
'
~
: tbb
.....___.____,;
vCFF
t-+
(s)
Fig. 11: Current development diagram MIG (MIX, CO.)
10.13 ·15·

LORCH
14 Messages
14.1 Sta tu s messages
'-- ~~~~~~~~~-
0 An enror code is displayed in t he 7-segment display
in the event
of a malfunction. You can switch over
between error code and sub-error(sub code) in the 7
segme nt display by pushing the button 44.
Code Note Ca u se
HOS Short-circuit Short-circuit in the outputcircuit
Messages
After the message has been output, the
machine will only function to a limited ex-
tent; the error must be corrected as quick ly
as possible.
The status message can
be de let ed by
pressing
the control knob 48.
P ossJb le remedy
Eli minate the short-circuit (pick up
electrode holder, ...)
H30 Configuration Component group recogniti
on faulty Inform Service
H31 Communication CAN bus communication faulty Check con
ne cted devices and CAN
connections
H34 Fans Fan curre
nt faulty Inform Service
Tab. 5: Status messages
14.2 Er r or messages
0 An error cod e is displayed in the 7- se gm ent displ ay
in the event of a malfunction. You can switch over
between error code and sub-e rr or ( sub code) in the 7
segmen t displ ay by pushing a ny button.
CD
As long as there is an error code on dis-
play weld ing is not possible.
Code.
E11ror
Ca u se
Poss i ble remedy
E01
Excessive temperature Duty cycle exceeded Allow switched-on machine to cool
down fo r a few minutes
Dust
fi lter contaminated Replace dust filter
E02 Overvoltage Mains voltage too high Check mains voltage
E04-1 Protective earth conductor
Fa u lt current to protective earth con- Connect the welding earth le ad
monitoring ductor
E06 Overvoltage secondary Initial voltage too
hi gh Inform Service
E07 EEPROM Communication with EEPROM defec- Switch machine
off and on again, ex -
tive ecute master reset
E08-1 Excess motor voltage Motorvoltage too high Inform Service
E08-2 Motor power supply Err
or in motor power supply Inform Service
E08-3 Overcurrent
on motor Motor current continuously t
oo high Reduce motor load
EOS -10 Torch connection Torch/torch connection error Check torch and torch connection.
Switch the equipment off and on again
E08-11
VII acquisition Voltage/current measuring systems Inform Service
faulty
E09 Vo ltage detection Voltage measuring system faulty Inform Servi
ce
E12 Power section Power section start-up
fa ulty Inform Service
E13 Temperature sensor Temperatu
re sensor not re ady for Inform Service
operation
E14 Supply voltage internal supply voltage too low Check mains voltages
E15 Current detection Error during curre
nt measurement Inform Service
E18
IOverload protection Safety switch device to protect elec- Inform Service
trical components
• 16. 10.13

Messages LORCH
Co de Error
Cause Possible remedy
E 22 Mains undervo lt a9e Mains voltage
on power unit is t oo Check mains voltag es
low
E25 Idle generator Idle generator raulty Inform Servi ce
E30 Error configuration Faulty or wrong pc- board, wrong Inform Service
software sys t em installed
E 31 Communications fault CAN bus commu nication fa ulty Switch the equipment offand on again
E32 FP GA FP GA faulty Inform Se rv ice
E 33 Power section Power module
not symmetrical Inform Service
E34 Fans Fan current
fa ulty Info rm Service
E40 Voltage detection Voltage measurement faulty
at the Inform Service
socket
Tab . 6. Errormessages
10.13 -17-

LORCH
15 Welding basics
15.1 St ick electrode wel din g
<-- - ----
Coated st ick electrodes are used for the widely-u se d
manual metal arc welding process (stick electrode weld-
ing). The coating of the electrode melts off during the
weldi ng process together wi th the co re wire. T he coating
gene
ra tes the shielding gas. Additionally the burning-
off coating compensates alloy elements. which are de-
stroyed in the molten pool. A slag layer forms on top of
thewelding seam. which covers and protects the cooling
welding se
am againstthe a ir .
The coatings
of the electrodes differ according to thick-
ness and type, i. e. chemical composition. This re sults in
different welding properties and con seq uently different
applications for t
he e'lectrodes. Types a nd nomenclature
a
re defined in DIN EN 499 (forme rl y 1913).
-'--- Stick electrode
Base
me ta l
15.2 TIG weld ing
The TI G welding process is a universally-applicable pro-
cess which creates high quality joint s.
T he electrode of t he TIG p ro cess consists of non-melting
tungsten, t
he shielding gas is an inert g as . In English
usage we
sp eak ofTIG welding ("Tungsten" = Wolfram ).
Inert gas is chemically neut ra l and does not react with
the weld meta
l. Inert gases are, e.g. arg on , helium and
their mixtures. Usually pure argon (99.9%) is used. The
welding g
as must be d ry . DIN 32 526 defines the differ-
ent types of shielding gas.
TI G wel ding process basics
A non-melting tungsten electrode is clamped with a col-
let into a gas or water-cooled torch. The arc burns be-
tween the tungsten electrode and the workpiece in an
in e rt shielding gas atmosphere. T hu s the tungsten elec-
trode acts as an arc carrier. The arc melts the workpiece
point by point and forms theweld pool. The shieldi
ng gas
escapes through the gas nozzle. This gas protects the
tungsten electrode, the arc and t
he molten pool against
t
he su rrounding air. This prevents undesired oxida ti on.
Con
seq uently, po or welding results may occur due to
tro
ub le with the shielding gas supply.
In case additional filler material is required. filler ~1\re
is supplied either manually, as in gas name we ldin g, or
-18 -
We lding bas ic s
automatically by means of a cold wi re feeder. The filler
wire must be equally or mo re highly alloyed than the
base mater
ia l. Fla nge and corner welds can be crea te d
easily without filler wire.
Sh ieldi ng gas
B
as ically, both DC and AC may be used for TIG welding.
The current mode and pol
ar ity depend on the material to
be welde
d.
No n or low-alloyed steel, high-alloyed steel and copper,
as well as titan
iu m a nd tantalum are welded with DC .
The electrode is connected at the minus pole because of
the stronger
cu rrent loading.
When welding aluminium and nnagnesium as well
as
theira ll oys, AC must be used in order to tear up the high-
melti ng and tough oxide skin which forms on the molten
pool or which is present on the base metal. If t
he oxide
skin is missin
g. e.g. there has been w el ding on the same
part for a longer tim
e, the arc can be un sta ble or break
up from time to
ti m e.
Shape of the electrode tip
Tungsten electrodes always have to be ground length-
wi se because crosswise g ri nd ing marks cause an un-
steady arc.
10 .13

Welding basics
Weldi ng current[A]
10- 50
50- 200
> 200
10.13
Electrode angle
15 °-30 °
30° -45 °
45 °- 75°
LORCH
The shape of the electrode for DC welding has to be
and remain as sharp as a pencil. The angle
of the point
depends on the
we ldi ng current. When AC weldi ng , ii is
suffici
en t to sharpen the edge of the electrode slightly.
Aftera short time,a roundto slightly convex form is built.
Ifthe electrode tip is polluted due to dipping into the weld
pool or touching the filler wi
re , the respective part of t he
electrode must be completely ground off. Restore t he
o ri ginal, pointed shape. Grind in longitudinal direction.
-19 -

LORCH
Fund amentals of the MIG/MAG welding process
16 Fundamentals ofthe MIG/MAG welding process
-~"'--'"~~~~~~~~~~~~~~~~
16.1 Princip le of the MIG/MAG welding
process
The wire feed rollers feed the wire electrode from the
reel to the contact tip. An arc is created between the wire
electrode and the workpiece. The wire electrode thus
becomes the arc carrier. The arc melts the workpiece
point by point and forms the weld pool. The wire elec-
trode melts a nd drips into the weld pool,thus fo rm i ng t he
filler metal. The inert gas flows from the gas nozzle and
protects the arc and weld pool from atmospheric gases.
Wire electr od£-- - -:
G as noz -- - ---"
~Bntact ti~: -= ~ ~~~
Sh ielding -,..-- -===-- ___,.~
gas
Welding
,._flem
Fig. 12: MIG/MAG welding process es
(!>
Powe r source
t:I
There a re two types of metal shielding-gas welding
that are diffe re nt iated by the type of shielding gas that
is used: metal inert gas welding (MIG), inert shielding
gas) and metal active gas weldi ng (MAG, active shield-
ing gas ).
Welding
Shielding gas
process inert act i ve
MIG
He li um (He) Ar gon (Ar)
mixt u re of Ar/He
MAG-C
Ca rb on di ox id e
100 % C02
MAG-M
Mixtures ofAr/
C02Ar/02
Tab. 7: MIG/MAG welding processes
The welding processes are further differentiated by arc
type.T
his means that there are differences in the form of
the arc, short circuit tendency and metal transfer mode.
Selection of the type of arc is only possible to a limited
extent e. g. when short arc welding. Short arc welding is
possible using all metal shielding gas welding processes
by the selection of the suitable current intensity and the
associated arc voltage, alt
ho ugh the short circuit fre-
quency and drop size are very different, according to the
shielding gas being use d.
-20 -
16 .2 Arc ty pes
Short arc
This type of arc is particularly suited to the welding of
thin sheets, in root layers and for welding in restric te d
locations because of its relatively "cold"weld flow. In th is
case , the weldi ng takes place with a very short arc. at
low arc voltage and at low cu rre nt intensity. Due to the
su
rf ace tens io n of the me lt pool, t he drop is drawn into
the
mo lt en metal and the arc is reignite d. This recurring
cyc le creates a continuous alternation between the short
circuit and the arcing period.
CD
The transi ti on from short to spr ay arc is de-
pendent upon the gas mixture and the wire
diameter.
Transiti on arc
A transi ti on arc is used for medium plate thickness and
for vertical down welds. The materi
al transfer tales place
both in short ci rcu it and in free flow. This produces a re -
duced short ci rcu it index and a slightly "hotter" mo l ten
pool than in the short arc. Tra ns ition arc welding has a
higher melting
ra te than short arc, a nd is therefore more
economical.
Long arc
Lo ng arcs are typically used for welding under carbon
dioxide and under high
C0 2 containi ng gas mixtures in
the upper pe rf ormance ra nge. Long arc welding is not
re ally suitable for welding in tight spaces. Larger drops
fall into the molten pool largely by gravi ty. This some-
times involves short circuits whic
h, al the point or the
short circuit,
ca n produce spatter when the arc ignites
again. because of the upslope.
Sp ra y arc
Due to the thinness of the melt pool, spray arc welding
is not suitable for welding in tight spaces. It is used for
welding in the high
er power range using inert gases or
gas mixtures with high argon conten
t. The spray arc has
a very fine dro
p, short-circuit free material transfer.
10.13