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TEAMWELDER MMA 300 CEL, Operating Instructions Manual

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TEAMWELDER MMA 300 CEL Operating Instructions Manual Download Page 3

 

Contents 

Notes on the use of these operating instructions 

 

299-010300-TWD01 

21.09.2015

 

3

 

 

1 

Contents 

 

1

 

Contents .................................................................................................................................................. 3

 

2

 

Safety instructions ................................................................................................................................. 5

 

2.1

 

Notes on the use of these operating instructions .......................................................................... 5

 

2.2

 

Explanation of icons ....................................................................................................................... 6

 

2.3

 

General .......................................................................................................................................... 7

 

2.4

 

Transport and installation ............................................................................................................ 11

 

2.4.1

 

Ambient conditions ....................................................................................................... 12

 

2.4.1.1

 

In operation ................................................................................................... 12

 

2.4.1.2

 

Transport and storage ................................................................................... 12

 

3

 

Intended use ......................................................................................................................................... 13

 

3.1

 

Applications .................................................................................................................................. 13

 

3.1.1

 

MMA welding ................................................................................................................ 13

 

3.1.2

 

TIG (Liftarc) welding ..................................................................................................... 13

 

3.2

 

Machine variants .......................................................................................................................... 13

 

3.2.1

 

Voltage reduction device 

– VRD machine version ....................................................... 13

 

3.3

 

Documents which also apply ....................................................................................................... 14

 

3.3.1

 

Warranty ....................................................................................................................... 14

 

3.3.2

 

Declaration of Conformity ............................................................................................. 14

 

3.3.3

 

Welding in environments with increased electrical hazards ......................................... 14

 

3.3.4

 

Service documents (spare parts and circuit diagrams) ................................................ 14

 

3.3.5

 

Calibration/Validation.................................................................................................... 14

 

4

 

Machine description 

– quick overview .............................................................................................. 15

 

4.1

 

Front view .................................................................................................................................... 15

 

4.2

 

Rear view ..................................................................................................................................... 16

 

4.3

 

Machine control 

– Operating elements ........................................................................................ 17

 

5

 

Design and function ............................................................................................................................. 19

 

5.1

 

General ........................................................................................................................................ 19

 

5.2

 

Transport and installation ............................................................................................................ 20

 

5.2.1

 

Adjusting the length of the carrying strap ..................................................................... 20

 

5.3

 

Machine cooling ........................................................................................................................... 21

 

5.4

 

Workpiece lead, general .............................................................................................................. 21

 

5.5

 

Mains connection ......................................................................................................................... 22

 

5.5.1

 

Mains configuration ...................................................................................................... 22

 

5.6

 

Notes on the installation of welding current leads ....................................................................... 23

 

5.7

 

MMA welding ............................................................................................................................... 25

 

5.7.1

 

Connecting the electrode holder and workpiece lead .................................................. 25

 

5.7.2

 

Selecting MMA welding ................................................................................................ 26

 

5.7.2.1

 

Arcforce (welding characteristics) ................................................................. 26

 

5.7.3

 

Hotstart current and Hotstart time ................................................................................ 27

 

5.7.4

 

Antistick ........................................................................................................................ 28

 

5.7.5

 

Advanced settings ........................................................................................................ 28

 

5.7.5.1

 

Arcforce correction (welding characteristics) ................................................ 28

 

5.8

 

TIG welding .................................................................................................................................. 29

 

5.8.1

 

Shielding gas supply (shielding gas cylinder for welding machine) ............................. 29

 

5.8.1.1

 

Connecting the shielding gas supply ............................................................ 30

 

5.8.2

 

Connecting a TIG welding torch with rotating gas valve .............................................. 31

 

5.8.2.1

 

Setting the shielding gas quantity ................................................................. 32

 

5.8.3

 

TIG welding selection ................................................................................................... 33

 

5.8.4

 

TIG arc ignition ............................................................................................................. 33

 

5.8.4.1

 

Liftarc ignition ................................................................................................ 33

 

5.9

 

Advanced settings ........................................................................................................................ 34

 

5.9.1

 

Arc length restriction (USP) .......................................................................................... 34

 

5.9.2

 

Activating the welding current actual value display ...................................................... 35

 

5.10

 

Remote control ............................................................................................................................. 36

 

5.10.1

 

Manual remote control TW-RT1 19POL ....................................................................... 36

 

5.11

 

Voltage reducing device (VRD) ................................................................................................... 36

 

Summary of Contents for MMA 300 CEL

Page 1: ...Operating instructions EN Welding machine MMA 300 CEL 299 010300 TWD01 21 09 2015 ...

Page 2: ...s explicitly excluded This liability disclaimer is regarded as having been accepted by the user when the system is commissioned The manufacturer can neither monitor the compliance with these instructions nor the conditions and methods employed during the installation operation use and maintenance of the machine An incorrectly performed installation can lead to material damage and injure persons as...

Page 3: ...ral 19 5 2 Transport and installation 20 5 2 1 Adjusting the length of the carrying strap 20 5 3 Machine cooling 21 5 4 Workpiece lead general 21 5 5 Mains connection 22 5 5 1 Mains configuration 22 5 6 Notes on the installation of welding current leads 23 5 7 MMA welding 25 5 7 1 Connecting the electrode holder and workpiece lead 25 5 7 2 Selecting MMA welding 26 5 7 2 1 Arcforce welding characte...

Page 4: ...l test 38 6 2 2 Monthly maintenance tasks 38 6 2 2 1 Visual inspection 38 6 2 2 2 Functional test 38 6 2 3 Annual test inspection and testing during operation 39 6 3 Disposing of equipment 39 6 3 1 Manufacturer s declaration to the end user 39 6 4 Meeting the requirements of RoHS 39 7 Rectifying faults 40 7 1 Error messages power source 40 7 2 Resetting welding parameters to the factory settings 4...

Page 5: ...he hazard is also highlighted using a symbol in the page margin CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury The safety information includes the CAUTION keyword in its heading with a general warning symbol The risk is explained using a symbol on the edge of the page CAUTION Working and operating procedures which must be followed p...

Page 6: ...users must observe Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu 4 s Time display example wait 4s press Interruption in the menu display other setting options possible Tool not required do not use Tool required use ...

Page 7: ...shocks and burns on contact Even low voltages can cause you to get a shock and lead to accidents Do not touch any live parts in or on the machine Connection cables and leads must be free of faults Switching off alone is not sufficient Place welding torch and stick electrode holder on an insulated surface The unit should only be opened by specialist staff after the mains plug has been unplugged Onl...

Page 8: ... accidents if these safety instructions are not observed Non observance of these safety instructions is potentially fatal Carefully read the safety information in this manual Observe the accident prevention regulations in your country Inform persons in the working area that they must observe the regulations Danger when coupling multiple power sources Coupling multiple power sources in parallel or ...

Page 9: ...g currents Stray welding currents can destroy protective earth conductors damage equipment and electronic devices and cause overheating of components leading to fire Make sure all welding leads are securely connected and check regularly Always ensure a proper and secure electrical connection to the workpiece Set up attach or suspend all conductive power source components like casing transport vehi...

Page 10: ...dard The user is responsible for any interference caused by welding In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area the user must consider the following see also EN 60974 10 Appendix A Mains control signal and telecommunication lines Radios and televisions Computers and other control systems Safety equipment The health of neighbouring persons e...

Page 11: ...uitable for transport by hand only The machine may not be lifted by crane or suspended CAUTION Risk of tipping There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to IEC 60974 1 Set up and transport the machine on level solid ground Secure add on parts using suitable equipme...

Page 12: ...ities of dust acid corrosive gases or substances may damage the equipment Avoid high volumes of smoke vapour oil vapour and grinding dust Avoid ambient air containing salt sea air Non permissible ambient conditions Insufficient ventilation results in a reduction in performance and equipment damage Observe the ambient conditions Keep the cooling air inlet and outlet clear Observe the minimum distan...

Page 13: ...and the molten pool There is no external protection any protection against the atmosphere comes from the electrode 3 1 2 TIG Liftarc welding TIG welding procedure with arc striking by contact with the workpiece and subsequent removal of the electrode 3 2 Machine variants 3 2 1 Voltage reduction device VRD machine version To increase safety particularly in hazardous environments like shipbuilding p...

Page 14: ...3 Welding in environments with increased electrical hazards In compliance with IEC DIN EN 60974 VDE 0544 the machines can be used in environments with an increased electrical hazard 3 3 4 Service documents spare parts and circuit diagrams DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment damage the unit must only be repaired or modified by specialist s...

Page 15: ...ransport bar 3 Machine control See 4 3 Machine control Operating elements chapter 4 Cooling air inlet 5 Connection socket 19 pole Remote control connection 6 Connection socket welding current TIG Connection for workpiece lead MMA Electrode holder or workpiece lead connection 7 Machine feet 8 Connection socket welding current Electrode holder or workpiece lead connection 9 Carrying strap ...

Page 16: ...Machine description quick overview Rear view 16 299 010300 TWD01 21 09 2015 4 2 Rear view Figure 4 2 Item Symbol Description 0 1 Main switch machine on off 2 Cooling air outlet 3 Mains connection cable ...

Page 17: ...elding can continue without any further measures 3 Welding data display 3 digit Displays the welding parameters and the corresponding values 4 Switch display button AMP Welding current display VOLT Welding voltage display 5 Welding process button MMA welding TIG welding 6 Arcforce button welding characteristics according to electrode type 7 Select welding parameters button This button is used to s...

Page 18: ...achine control Operating elements 18 299 010300 TWD01 21 09 2015 Item Symbol Description 0 10 AMP Hotstart current signal light 50 to 200 of the main current 11 sec Hotstart time signal light 0 1 s to 20 s 12 AMP Main current signal light ...

Page 19: ...the welding current connection If the welding current connections are not locked connections and leads heat up and can cause burns if touched Check the welding current connections every day and lock by turning in clockwise direction if necessary Risk from electrical current If welding is carried out alternately using different methods and if a welding torch and an electrode holder remain connected...

Page 20: ... be lifted by crane or suspended CAUTION Installation site The machine must not be operated in the open air and must only be set up and operated on a suitable stable and level base The operator must ensure that the ground is non slip and level and provide sufficient lighting for the place of work Safe operation of the machine must be guaranteed at all times 5 2 1 Adjusting the length of the carryi...

Page 21: ...not allow metal parts dust or other objects to get into the machine 5 4 Workpiece lead general CAUTION Risk of burns due to incorrect connection of the workpiece lead Paint rust and dirt on the connection restrict the power flow and may lead to stray welding currents Stray welding currents may cause fires and injuries Clean the connections Fix the workpiece lead securely Do not use structural part...

Page 22: ...operating instructions The resulting network has to be suitable for operating devices according to protection class 1 5 5 1 Mains configuration The machine may be connected to a three phase system with four conductors and an earthed neutral conductor a three phase system with three conductors of which any one can be earthed e g the outer conductor Figure 5 2 Legend Item Designation Colour code L1 ...

Page 23: ... power sources without HF igniter MIG MAG for as long and as close as possible in parallel Lay the workpiece lead and hose package of power sources with HF igniter TIG for as long as possible in parallel with a distance of 20 cm to avoid HF sparkover Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences Always keep leads as short as possible For optimum we...

Page 24: ...WD01 21 09 2015 Use an individual welding lead to the workpiece for each welding machine Figure 5 4 Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Always keep leads as short as possible Lay any excess cable lengths in meanders Figure 5 5 ...

Page 25: ...ns from the electrode manufacturer given on the electrode packaging 5 7 1 Connecting the electrode holder and workpiece lead Figure 5 6 Item Symbol Description 0 1 Electrode holder 2 Connection socket for welding current Electrode holder or workpiece lead connection 3 Workpiece 4 Connection socket welding current Workpiece lead or electrode holder connection Insert cable plug of the electrode hold...

Page 26: ...ctrode types at low current strengths with a short arc in particular The selectable electrode characteristics on the machine control are guideline values Every characteristic can also be optimised for the relevant electrode types and their welding properties The electrode types used must be selected on the machine control to achieve the optimum welding properties of the electrode types Control ele...

Page 27: ...at this current until the hotstart time in seconds has elapsed factory setting 1 second The hotstart current then reduces to the main current set Symbol Meaning AMP Main current AMP Hotstart current sec Hotstart time Figure 5 8 Hotstart current Control element Action Result n x Signal light AMP lights up Hotstart current is set as a percentage of the main current 50 to 200 Hotstart time Control el...

Page 28: ... or optimised for the welding task 5 7 5 1 Arcforce correction welding characteristics To change the advanced setting parameters hold down the Welding parameters button for 2 seconds after selecting the welding process The following diagram shows the setting options ENTER 2 s EXIT 2 s Figure 5 10 Display Setting selection Arcforce correction setting 8 to 10 factory setting 0 Increase value harder ...

Page 29: ...ylinders in the holders provided for them and secure with fixing devices Avoid heating the shielding gas cylinder CAUTION Faults in the shielding gas supply An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results In addition a blocked shielding gas supply may result in the welding torch being destroyed Always ...

Page 30: ...en the pressure regulator screw connection on the gas bottle valve to be gas tight Screw the shielding gas connection of the welding torch to the pressure reducer on the shielding gas cylinder Slowly open the gas cylinder valve Open the rotating valve on the welding torch Before each welding process the rotating valve must be opened after the welding process it must be closed Set the required amou...

Page 31: ...gulator 4 Welding torch 5 Connection socket welding current Welding current lead connection for TIG welding torch Insert the welding current plug on the welding torch into the welding current connection socket and lock by turning to the right Insert the cable plug on the work piece lead into the welding current connection socket and lock by turning to the right Screw the shielding gas connection o...

Page 32: ...nd burning on contact Keep the welding torch electrically insulated from persons animals or equipment during the setting procedure Incorrect shielding gas setting If the shielding gas setting is too low or too high this can introduce air to the weld pool and may cause pores to form Adjust the shielding gas quantity to suit the welding task Rule of thumb for the gas flow rate Diameter of gas nozzle...

Page 33: ...rkpiece a Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece liftarc current flowing regardless of the main current set b Incline the torch towards the torch gas nozzle until there is a gap of approx 2 3mm between the tip of the electrode and the workpiece arc ignites current increases to the main current set c Lift off the torch and swivel to the normal position En...

Page 34: ...st possible breadth of applications the following parameters can be adjusted or optimised for the welding task 5 9 1 Arc length restriction USP EXIT ENTER 2 s 2 s Figure 5 14 Display Setting selection Arc length restriction on Function switched on TIG factory setting off Function switched off MMA factory setting ...

Page 35: ...oint value parameter rcd off After switching over to the actual value display parameter rcd on the following is displayed The setpoint value is displayed in open circuit mode when no welding current is flowing If welding current is flowing the welding data display switches over to the actual value After welding the setpoint value is displayed once more ENTER 2 s EXIT 2 s Figure 5 15 Display Settin...

Page 36: ...vice VRD To increase safety particularly in hazardous environments like shipbuilding pipe construction or mining the machine is equipped with the VRD Voltage reducing device voltage reduction device The VRD signal light is illuminated when the voltage reduction device is operating without fault and the output voltage is reduced to a value specified in the relevant standard see technical data The v...

Page 37: ... via the reduced flow of cooling air The filter must be disassembled and cleaned regularly depending on the level of dirt blow out with compressed air These accessory components can be retrofitted as an option Figure 5 16 Item Symbol Description 0 1 4 fixing screws for dirt filter 2 Dirt filter with fixing plate 3 Cooling air inlet Fix dirt filter with 4 fixing screws on the front of the casing co...

Page 38: ...parts please quote the machine type serial number and item number of the machine as well as the type designation and item number of the spare part 6 1 General When used in the specified environmental conditions and under normal operating conditions this machine is largely maintenance free and requires a minimum of care There are some points which should be observed to guarantee fault free operatio...

Page 39: ... January 27th 2003 used electric and electronic equipment may no longer be placed in unsorted municipal waste It must be collected separately The symbol depicting a waste container on wheels indicates that the equipment must be collected separately This machine is to be placed for disposal or recycling in the waste separation systems provided for this purpose According to German law law governing ...

Page 40: ...ause Remedy E 1 Electronics error Switch the machine off and back on again If the error persists inform the service dept E 2 Temperature error Allow machine to cool down E 3 Electronics error See E 1 E 4 Electronics error See E 1 E 5 Electronics error See E 1 E 6 Balancing error in voltage recording Switch off the machine place the electrode holder in an insulated position and switch the machine b...

Page 41: ...o the factory settings All customised welding parameters that are stored will be replaced by the factory settings RESET AM P VOLT l 0 Figure 7 1 Display Setting selection Calibration The machine will be calibrated for approx 2 seconds each time it is switched on Initialising Keep the push button pressed until InI is shown on the display ...

Page 42: ...0 300 A 220 A 170 A 300 A 240 A 190 A Load cycle 10 min 60 DC 6 min welding 4min pause Open circuit voltage 107 V Mains voltage tolerances 3 x 400 V 25 to 20 Frequency 50 60 Hz Mains fuse safety fuse slow blow 10 A Mains connection lead H07RN F4G2 5 Max connected load 12 1 kVA 8 3 kVA Recommended generator rating 16 3 kVA cos efficiency 0 99 88 Insulation class protection classification H IP 23 Am...

Page 43: ...Accessories Internet 299 010300 TWD01 21 09 2015 43 9 Accessories 9 1 Internet For the accessories available for your product go to www teamwelder com Figure 9 1 ...

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