Operation Manual - Merkle Landshut

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
.
Content
1st
2.
page
Security indications before introduction
3
Accident prevention regulations
2nd1
3
Safety instructions
3
3rd
Duty cycle
5
4th
Instructions to avoid interferences due to electromagnetic influences EMC
5
5.
Technical Data:
7
5th1
TIG Welding Unit, model Insquare W 300 / 420 DC:
7
5th2
TIG Welding Unit, model Insquare W 300 / 420 AC-DC:
9
5th3
TIG Welding Unit, model Insquare W 600 AC-DC:
6.
Set Up
12
14
6th1
Installation of the Machine
14
6th2
Main Supply
14
6th3
Welding Torch
14
6th4
Earth Lead (Work Cable)
14
6th5
Electrode holder
14
6th6
Transport
14
7.
TIG-Welding Unit, model Insquare W 300 /420 / 600
7th1
Automatic safety switch off
15
15
8.
Operation of the Unit
19
9.
TIG welding
23
9th1
preparing-values at DC welding
23
9th2
preparing-values at AC welding
24
10.
10th1
MMA stick electrode –welding
24
Standard values for the metal arc welding
25
11.
Display
25
12.
Trouble Shooting
26
13.
Cleaning
27
14.
Maintenance and Accident Prevention
27
15.
Inspection
27
1
16.
TIG hand welding torch - and spare parts
28
16th1
TIG Hand Welding Torch, Model TH 450 W, water cooled,
28
16th2
TIG Hand Welding Torch, Model TH 600 W, water cooled,
33
17.
Spare parts and wiring diagram
37
17th1
Spare part list TIG Insquare W 300/420 DC
37
17th2
Wiring diagram INS 300-420 DC
38
17th3
Spare part list TIG Insquare W 300 AC/DC
43
17th4
Wiring diagram INS W 300 AC/DC
44
17th5
Spare part list TIG Insquare W 420 AC/DC
50
17th6
Wiring diagram INS W 420 AC/DC
51
17th7
Spare part list TIG Insquare W 600 AC/DC
57
17th8
Wiring diagram INS W 600 AC/DC
59
18.
EU-Conformity Attestation INS 300-420
69
19.
EU-Conformity Attestation INS 600
70
2
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.
2.
Accident prevention regulations
The following accident prevention regulation is applied for welding with TIG - welding unit,
model INSQUARE W 300/420 DC, W 300/420 AC/DC and W600 AC/DC,
BGV D1 (earlier VBG 15) * Welding, cutting and allied processes.
A copy of this regulation should be readily accessible in every welding shop. The stipulations
of this regulation are to be observed in the interests of safe and correct welding operation.
* Available from the trade association responsible or
Carl Heymanns-Verlag, Luxemburger Strasse 449, 50939 Cologne.
2nd1 Safety instructions
This unit is manufactured according to the requirements and stipulations of EN 60974.1 /
VDE 0544 part 1. The accident prevention regulations “Welding, cutting and allied
processes”
BGV D1 (earlier VBG 15) of the trade association for precision engineering and electrical
engineering are as well valid.
1) In case of an accident, the welding unit must be disconnected from the mains
immediately.
2) If electrical contact voltages arise, switch off the unit immediately, disconnect it from
the mains and proceed to inspection by a qualified electrician or by our Service
Department.
3) Before opening the unit, disconnect it from the mains supply.
4) Repair work may only be carried out by a skilled electrician or by our Service
Department.
5) Before the unit is put to operation, check it visually, as well as the torch and all cables
and connectors regarding possible external damages.
6) Personal protective equipment in accordance with DIN EN 175, DIN EN 379 and
DIN EN 169.
During the work, the welder’s body must be completely protected against radiation
and burns by means of protective clothing and face protection. Long gloves, aprons
and welding shields with welding filters conforming to DIN EN 470-1 and BGR 189
must be worn. Synthetic clothing are excluded. Shoes must be closed, not opened (due
to spatters). If necessary, protective headwear must be worn (e.g. for overhead
welding). If cover glasses are used, these must be in accordance with the norms
specified above. As additional protection for the eyes against UV radiation, safety
goggles with side shields and corresponding face protection in accordance with
BGR 192 and BGI 553 must be worn.
Accident prevention regulation BGV D1 § 27 stipulates that it is the responsibility of
the employer to provide suitable personal protective equipment, while § 28 stipulates
that it is the responsibility of the insured to wear suitable clothing.
3
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. Wear dry, undamaged work clothing, long gloves and footwear
with rubber soles. Ventilate rooms, install extraction systems if required, and wear
respiratory protective equipment if necessary (see Procedural instructions BGV D1
§ 27 and BGI 533, Section 5).
8) In order to prevent stray currents and the effects thereof (e.g. destruction of electrical
protective ground conductors), the welding return cable (workpiece cable) must be
connected directly to the workpiece to be welded or to the table (e.g. welding table,
grid-type welding table, workbench) supporting the workpiece (see BGV D1 § 20).
When installing the ground connection, assure that there is a good electrical contact
(remove rust, paint, etc.).
9) During welding pauses, the welding torch is to be laid down on an insulated surface or
hung up in such a way that it is not in contact with the workpiece and its support
connected to the welding power source (see § 20 BGV D1).
In the case of longer work pauses, the welding unit must be switched off and the gas
cylinder valve must be closed.
10) The shielding gas cylinder must always be protected against tumbling downing using a
safety chain.
11) Under no circumstances the unit may be put into operation while it is opened
(e.g. for repair work). Apart from the safety regulations, sufficient cooling of the
electrical components provided by the fan cannot be guaranteed.
12) In accordance with BGV D1 § 5, people in the vicinity of the arc must also be
informed of the hazards and protected against them. Safety partitions (“welding safety
curtains”) must be erected in accordance with DIN EN 1598.
a. No welding work may be carried out on containers in which gases, fuels, mineral oils
or similar substances have been stored Öeven if they have been empty for a long
timeÕ (risk of explosion). See § 31 of accident prevention regulation BGV D1.
14) Welds which will be subjected to high loads and which need to meet specific safety
requirements may only be carried out by specially trained and qualified welders.
15) Do never bring the torch close to your face.
16) In areas at particularly high risk of fire, the welder must obtain a welding permit and
have this on his person throughout the duration of the welding work. On completion of
welding, a fire-guard must be delegated to ensure fire protection.
17) Ventilation measures must be applied in accordance with BGI 553, Section 9.
18) The hazard to eyesight must be indicated by means of a sign at the work site
"CAUTION! Do not look into the arc!".
4
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.
4th Instructions to avoid interferences due to electromagnetic influences
EMC
The welding unit has been manufactured in accordance with the requirements of guideline
EN 60974-10 regarding electromagnetic compatibility. It is nonetheless the responsibility of
the user to ensure that the welding equipment is installed and operated in accordance with the
manufacturer’s instructions. If electromagnetic interference is detected, it is the responsibility
of the user of the welding equipment to find a solution with the technical assistance of the
manufacturer. In some cases, it may be sufficient simply to ground the welding current
circuit. In other cases, it may be necessary to build a complete shield for the welding power
source and workpiece using the input filters. In all cases, electromagnetic interference must be
reduced to avoid any possible malfunctions.
Note: For safety reasons, the welding current circuit may or may not be grounded. No
modifications may be made to the grounding without the approval of an expert who is able to
determine whether the changes might increase the risk of accidents, e.g. by allowing parallel
welding current return paths which could destroy the ground conductors of other equipment.
Further instructions are contained in TEC 974-XX "Arc welding equipment – installation and
use".
a)
¾
¾
¾
¾
¾
¾
b)
1)
Evaluation of the installation site
Before installing the welding equipment, the user must evaluate potential
electromagnetic problems in the vicinity. The following must be taken into
consideration:
Other power cables, control cables, signal and telecommunication cables above, below
and next to the welding equipment
Radio and television transmitters and receivers
Computers and other control devices
The health of people in the vicinity, e.g. use of heart pacemaker and hearing aids
Calibration and measuring equipment
Interference immunity of other devices in the vicinity. The user must ensure the
electromagnetic compatibility of other devices used in the vicinity. This may require
additional safety measures.
Procedures to reduce emitted interference
Mains supply
Welding equipment is to be connected to the mains in compliance with the
recommendations of the manufacturer. If interference occurs, it may be necessary to
take additional precautions, e.g. filters for the mains connection. Make sure that the
power cable of welding equipment is installed in a fixed position shielded by means of
a metal conduit or similar. The entire length of the shield must be electrically
connected. The shield must be connected to the welding power source in the way to
obtain a good electrical contact between the metal conduit and the housing of the
welding unit.
5
2)
3)
4)
5)
6)
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.
Welding cables
Welding cables should be kept as short as possible and routed close together on or
near the floor.
Equipotential bonding
It is advisable to interconnect all metallic parts in and next to the welding equipment.
Metallic parts connected to the workpiece can, however, increase the risk of the
welder receiving an electric shock by touching these metallic parts and the electrode
simultaneously. The welder must be electrically insulated against all these connected
metallic parts.
Grounding the workpiece
If the workpiece is not connected to the ground for electrical safety reasons, or due to
the size and position of the workpiece, e.g. steel structure or outer wall of a ship,
grounding the workpiece may in some cases, but not all, reduce emitted interference. It
must be ensured that grounding the workpiece will not increase the risk of accidents
for the user and cannot cause the destruction of other electrical equipment. If
necessary, the grounding of the workpiece must be carried out by means of a direct
connection to the workpiece. In countries where a direct connection is prohibited, the
connection must be made by means of suitable reactors, selected in accordance with
national regulations.
Shielding
Selective shielding of other cables and devices in the vicinity can reduce interference
problems. For special applications, it may be worth considering shielding the entire
welding system.
6
5.
5th1
Technical Data:
TIG Welding Unit, model Insquare W 300 / 420 DC:
Insquare W 300 DC
Insquare 420 DC
Primary:
Power supply:
Frequency:
cos phi:
3 x 400 V
50 (60) Hz
0.95
3 x 400 V
50 (60) Hz
0.95
TIG DC operation:
Open circuit voltage:
Welding voltage:
Welding current:
Duty cycle 60 %:
Duty cycle 80 %:
Duty cycle 100 %:
Prim. cont. power:
Prim. cont. current:
Prim. max. current:
80 V
10 - 22.8 V
5-320 A
320 A (10 min.)
300 A (10 min.)
260 A (40°C)
9.5 kVA
13.7 A
19 A
80V
10-26,8 V
5-420 A
420 (10 min.)
400 (10 min.)
310 A (40°C)
12 kVA
17,4 A
28 A
MMA/stick electrode operation:
Stick electrodes:
1.5-6 mm
1.5-6 mm
Open circuit voltage:
80 V
80 V
Welding voltage:
20 - 32.8 V
20-36,8 V
Welding current:
5-320 A
5-420 A
Duty cycle 50 %
420 A (10 min.)
Duty cycle 60 %:
320 A (10 min.)
400 A (10 min.)
Duty cycle 80 %:
300 A (10 min.)
Duty cycle 100 %:
260 A (40°C)
300 A (40°C)
Prim. cont. power:
13.1 kVA
14,5 kVA
Prim. cont. current:
19 A
21 A
Prim. max. current:
22 A
34 A
Protection class:
IP 21
Insulation class:
H
Cooling:
AF
Main switch:
3-phase
Welding modes:
TIG DC,
MMA/stick electrode
Selector 1:
current 1, time 1,
upslope and downslope time,
start current, final current,
spot welding time,
gas pre- and post-flow time
Selector 2:
current 2, time 2,
(for pulsation),
hotstart time a. current,
arc force, stick electrode mm ∅,
display voltage
Adjusting:
2 rotary switches
for slectors 1 and 2
7
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,
test, programming
Program storage:
20 programs
Gas pre-flow time:
0-3 s
Gas post-flow time:
0-25 s
Up slope time:
0-2 s
Down slope time:
0-20 s
Spot welding time:
0.1-2.5 s
Pulsation slow:
10 ms-2.5 s
Pulsation fast:
50 Hz-5 kHz
Hotstart time:
0-1.5 s
Hotstart current:
10-200 %
Arc force:
100-250 %
Button:
program selection
LEDs:
mains ON, temperature
protection, failure,
hold function,
start current, up slope, down
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:
4 x 4 mm², 5 m long
Gas hose:
2 m long
Weight:
115 kg (W 300 DC)
125 kg (W 420 DC)
Dimensions L x W x H:
910 x 600 x 910 mm
incl. gas bottle holder
Gas bottle holder:
10 - 20 - 50 l cylinders
Lifting eyes:
4 pieces (option)
Standard accessories:
Earth lead 50 mm², 4 m long
with plug and earth clamp (W 300 DC)
Earth lead 70 mm², 4 m long
with plug and earth clamp (W 420 DC)
Regulator argon/CO2, single stage
022.1.0402
022.1.0408
012.0.0300
8
5th2
TIG Welding Unit, model Insquare W 300 / 420 AC-DC:
Insquare W 300 AC-DC
Insquare 420 AC-DC
Primary:
Power supply:
Frequency:
cos phi:
3 x 400 V
50 (60) Hz
0.95
3 x 400 V
50 (60) Hz
0.95
TIG DC operation:
Open circuit voltage:
Welding voltage:
Welding current:
Duty cycle 60 %:
Duty cycle 80 %:
Duty cycle 100 %:
Prim. cont. power:
Prim. cont. current:
Prim. max. current:
80 V
10 - 22.8 V
5-320 A
320 A (10 min.)
300 A (10 min.)
260 A (40°C)
9.5 kVA
13.7 A
19 A
80 V
10-26,8 V
5-420 A
420 (10 min.)
400 (10 min.)
310 A (40°C)
12 kVA
17,4 A
28 A
TIG AC operation:
Open circuit voltage:
Welding voltage:
Welding current:
Duty cycle 60 %:
Duty cycle 80 %:
Duty cycle 100 %:
Prim. cont. power:
Prim. cont. current:
Prim. max. current:
80 V
10 - 22.8 V
5-320 A
320 A (10 min.)
300 A (10 min.)
260 A (40°C)
9.5 kVA
13.7 A
19 A
80V
10-26,8 V
5-420 A
420 (10 min.)
310 A (40°C)
12 kVA
17,4 A
28 A
MMA/stick electrode operation:
Stick electrodes:
1.5-6 mm
Open circuit voltage:
80 V
Welding voltage:
20 - 32.8 V
Welding current:
5-320 A
Duty cycle 50 %
Duty cycle 60 %:
320 A (10 min.)
Duty cycle 80 %:
300 A (10 min.)
Duty cycle 100 %:
260 A (40°C)
Prim. cont. power:
13.1 kVA
Prim. cont. current:
19 A
Prim. max. current:
22 A
Protection class:
Insulation class:
Cooling:
Main switch:
Welding modes:
1.5-6 mm
80 V
20-36,8 V
5-420 A
420 A (10 min.)
400 A (10 min.)
300 A (40°C)
14,5 kVA
21 A
34 A
IP 21
H
AF
3-phase
TIG DC (-), TIG DC (+),
TIG DC (-) w. start puls (+),
TIG AC "noise reduced",
9
Selector 1:
Selector 2:
Adjusting:
Digital displays:
Timer functions:
Ignition:
Energy control:
Operation modes:
Program storage:
AC frequency:
AC balance:
Gas pre-flow time:
Gas post-flow time:
Up slope time:
Down slope time:
Ignition impulse:
Spot welding time:
Pulsation slow:
Pulsation fast:
Hotstart time:
Hotstart current:
Arc force:
Button:
Button:
LEDs:
TIG AC "square arc",
TIG AC "balanced TIG",
MMA/stick electrode (-),
MMA/stick electrode (+),
MMA/stick electrode sinusodial,
MMA/stick electrode square arc
current 1, time 1,
upslope and downslope time,
start current, final current,
ignition impulse, spot w. time,
gas pre- and post-flow time
current 2, time 2,
(for pulsation),
AC balance, AC frequency,
hotstart time a. current,
arc force, stick electrode mm ∅,
display voltage
2 rotary switches
for slectors 1 and 2
2 displays with pre-indication
and hold function for current,
voltage, time, frequency
OFF, quick and slow pulsation,
spot welding time
OFF, high frequency,
lift arc
at the machine, at the torch,
hand remote control, foot pedal
2-stroke, 4-stroke, 4-stroke
with 2 currents, gas check,
test, programming
20 programs
50-200 Hz
9-91 %
0-3 s
0-25 s
0-2 s
0-20 s
0-100 ms
0.1-2.5 s
10 ms-2.5 s
50 Hz-5 kHz
0-1.5 s
10-200 %
100-250 %
test protection device
program selection
mains ON, temperature
protection, failure,
protection device, hold function,
start current, up slope, down
10
slope, current 1 + 2, final curr.
IGBT inverter
HF generator or lift arc
EN 60974-1 "S" / CE
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:
4 x 4 mm², 5 m long
Gas hose:
2 m long
Weight:
130 kg (W 300 DC)
140 kg (W 420 DC)
Dimensions L x W x H:
910 x 600 x 910 mm
incl. gas bottle holder
Gas bottle holder:
10 - 20 - 50 l cylinders
Lifting eyes:
4 pieces (option)
Power source:
Ignition:
Norm:
Torch connection:
Standard accessories:
Earth lead 50 mm², 4 m long
with plug and earth clamp (W 300 AC-DC)
Earth lead 70 mm², 4 m long
with plug and earth clamp (W 420 AC-DC)
Regulator argon/CO2, single stage
022.1.0402
022.1.0408
012.0.0300
11
5th3
TIG Welding Unit, model Insquare W 600 AC-DC:
Primary:
Power supply:
Frequency:
cos phi:
3 x 400 V
50 (60) Hz
0.95
TIG DC operation:
Open circuit voltage:
Welding voltage:
Welding current:
Duty cycle 60 %:
Duty cycle 100 %:
Prim. cont. power:
Prim. cont. current:
Prim. max. current:
80 V
10 - 34 V
20-600 A
600 A (10 min.)
500 A (40°C)
24.2 kVA
35 A
42 A
TIG AC operation:
Open circuit voltage:
Welding voltage:
Welding current:
Duty cycle 60 %:
Duty cycle 100 %:
Prim. cont. power:
Prim. cont. current:
Prim. max. current:
80 V
10 - 34 V
20-600 A
600 A (10 min.)
500 A (40°C)
24.2 kVA
35 A
42 A
MMA/stick electrode operation:
Stick electrodes:
Open circuit voltage:
Welding voltage:
Welding current:
Duty cycle 40 %:
Duty cycle 60 %:
Duty cycle 100 %:
Prim. cont. power:
Prim. cont. current:
Prim. max. current:
1.5-6 mm
80 V
20 - 44 V
20-600 A
600 A (10 min.)
550 A (10 min.)
450 A (40°C)
25.6 kVA
37 A
50 A
Protection class:
Insulation class:
Cooling:
Main switch:
Welding modes:
IP 21
H
AF
3-phase
TIG DC (-), TIG DC (+),
TIG DC (-) w. start puls (+),
TIG AC "noise reduced",
TIG AC "square arc",
TIG AC "balanced TIG",
MMA/stick electrode (-),
MMA/stick electrode (+),
12
Selector 1:
Selector 2:
Adjusting:
Digital displays:
Timer functions:
Ignition:
Energy control:
Operation modes:
Program storage:
AC frequency:
AC balance:
Gas pre-flow time:
Gas post-flow time:
Up slope time:
Down slope time:
Ignition impulse:
Spot welding time:
Pulsation slow:
Pulsation fast:
Hotstart time:
Hotstart current:
Arc force:
Button:
Button:
LEDs:
Power source:
Ignition:
Norm:
Torch connection:
MMA/stick electrode sinusodial,
MMA/stick electrode square arc
current 1, time 1,
upslope and downslope time,
start current, final current,
ignition impulse, spot w. time,
gas pre- and post-flow time
current 2, time 2,
(for pulsation),
AC balance, AC frequency,
hotstart time a. current,
arc force, stick electrode mm ∅,
display voltage
2 rotary switches
for slectors 1 and 2
2 displays with pre-indication
and hold function for current,
voltage, time, frequency
OFF, quick and slow pulsation,
spot welding time
OFF, high frequency, lift arc
at the machine, at the torch,
hand remote control, foot pedal
2-stroke, 4-stroke, 4-stroke
with 2 currents, gas check,
test, programming
20 programs
50-200 Hz
9-91 %
0-3 s
0-25 s
0-2 s
0-20 s
0-100 ms
0.1-2.5 s
10 ms-2.5 s
50 Hz-5 kHz
0-1.5 s
10-200 %
100-250 %
test protection device
program selection
mains ON, temperature
protection, failure,
protection device, hold function,
start current, up slope, down
slope, current 1 + 2, final curr.
IGBT inverter
HF generator or lift arc
EN 60974-1 "S" / CE
Euro connector, with 5-pole plug
13
Torch cooling:
Socket 50 mm²:
Socket 50 mm²:
Mains supply cable:
Gas hose:
Weight:
Dimensions L x W x H:
Gas bottle holder:
Lifting eyes:
integrated water cooling system
earth lead
electode welding cable
4 x 6 mm², 5 m long
2 m long
255 kg
1055 x 630 x 1290 mm
incl. gas bottle holder
10 - 20 - 50 l cylinders
4 pieces (option)
Standard accessories:
Earth lead 120 mm², 4 m long
with plug and earth clamp
Regulator argon/CO2, single stage
6.
022.1.0396
012.0.0300
Set Up
6th1 Installation of the Machine
Place the machine at least 0.80 m from a wall etc. to guarantee the cooling air can go
through the unit. The room temperature should not exceed 40°C.
The room were the unit is placed should have a low degree of humidity
(max. 50 % at 40°C, max. 90 % at 20° C).
The unit has passed the quality control in accordance with IP 21.
The air in the surroundings must be free from extreme quantities of dust, free from acides and
corrosive gases etc. Otherwise use air filters.
6th2 Main Supply
The main supply must be connected by a trained person. The main supply voltage is displayed
on the front or rear panel of the machine. 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. The clamp should be attached to a clean,
paint and rust free area on the work piece or on the welding table.
6th5
Electrode holder
Only use electrode holders with a proper insulation and a good contact with the
electrode.
6th6
Transport
If a transport by crane is required, the unit must be fixed at all lifting eyes.
The gas bottle is to be lost and decollates decollates advance.
14
7.
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 TIGwelding in DC, AC and for MMA/stick electrode welding. Continuous setting of the welding
current is up to 300 / 420 / 600A.
The units can be characterized by numerous features:
• inverter power source with continuous setting of the current
5 - 300 / 420A (W 300/420) and 20 – 600 A (W 600)
• 2-stroke, 4-stroke Operation
• two welding currents separately adjustable at the torch
• high frequency (HF) and Lift-arc ignition
• continuous setting of the down slope
• socket for remote control
• gas post-flow adjustable
• digital read out with pre-display and hold-function
• TIG pulsation as a Standard
• stick electrode operation:
1. Arc force:
increasing of the welding current in order
to avoid adherence of the electrode.
2. Hotstart function:
increasing of the start current to
assure a safe ignition.
3. Anti stick function:
In case of adherence of the electrode, the current
is switched off immediately. Reignition after separation
only is possible with a short retardation.
7th1
Automatic safety switch off
In TIG Operation the welding voltage is automatically switched off after 2 s, when no
welding current is established.
15
Jumper location on pcb ME-TF-1.2
Insquare W 300, W 420, W 600
16
Reduced front panel
JP 1 on pcb ME-TF-1.2 plugged
I1/t1
0
PULS
I2/t2
STROM/current I1
DC
ZEIT / time t1
AC
0
HF
ABSENKUNG/downslope
LIFT-ARC
I1
GAS
I1
STROM
I2
current I2
ZEIT
t2
time
DISPLAY: SPANNUNG
voltage
t2
AC BALANCE
+ (%)
AC FREQUENZ
frequency
I2
I1/t1
(%)
0
PULS
I2/t2
STROM/current I1
ANSTIEG/upslope
STARTSTROM/initial curr.
ZÜNDIMPULS
igniton pulse
GAS
DC
ZEIT / time t1
AC
PULS
0
ABSENKUNG/downslope
HF
ENDSTROM / final current
LIFT-ARC
PUNKTZEIT
timer spot welding
I1
GAS
I1
I1
I1
STROM
I2
current I2
DISPLAY: SPANNUNG
voltage
ZEIT
t2
time
HOTSTART - ZEIT
timer
t2
AC BALANCE
+ (%)
HOTSTART - STROM
current
AC FREQUENZ
frequency
STROMNACHREGELUNG
arc force
TIG-ELEKTRODE
mm
I2
(%)
GASTEST
TEST,PROG
Complete front panel
JP 1 on pcb ME-TF-1.2 unplugged
17
Front panel
1
12
7
5
9
3
2
15
14
I1/t1
I2/t2
S TROM/c urrent I1
ANSTI EG/ups lope
PROGRAMM-NR.
DC
ZE IT / time t1
STARTSTROM/initial curr.
ZÜNDIMPULS
GAS
AC
HAUPTSCHALTER
MAIN SWITCH
13
s
RMS
STATUS
0
HF
ENDSTROM / final current
L IFT-AR C
timer spot welding
I1
GAS
M
Q
C
I1
I1
U
CAN
P ULS
ABSENKUNG/downslope
PUNKTZEIT
igniton pulse
19
0
P ULS
s
Hz
kHz
HOLD
18
<48V
PT11
I1
A
s
Hz
Test
8
10
11
STROM
I2
current I2
DISPLAY: SPANNUNG
ZEIT
t2
time
HOTSTART-ZEIT timer
t2
voltage
ABSENKUNG-PILOTGAS
AC BALANCE
+ (%)
HOTSTART-STROM current NACHSTRÖMUNG-PILOTGAS
AC FREQUENZ
frequency
STROMNACHREGELUNG arc force
TIG-ELEKTRODE
I2
PILOTGASMENGE
KALTDRAHT
mm
6
4
(%)
G A ST E S T
TEST,PROG
16 17
E 2825-43
18
8.
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"
¾ Stick electrode-DC, plus-pole on electrode*
¾ Stick electrode-DC, minus-pole on electrode
¾ TIG-DC, plus-pole on torch electrode*
for extremly thin plates and metal foils, max.amps. 50A
¾ TIG-DC, minus-pole on torch electrode with positive
ignition pulse; improving ignition characteristics
welding highly oxidates sheets
¾ TIG-DC, minus-pole on torch electrode
standard position for TIG-DC-welding
¾ TIG-AC with positive ignition pulse, noice reduced
standard position for aluminium welding
¾ TIG-AC with positive ignition pulse, square wave
very stable arc even in pure aluminium
¾ Mixed-TIG-AC containing DC-parts
for welding without adding material and low loading of the torch electrode
¾ Stick electrode-AC, noice reduced
¾ Stick electrode-AC, square wave
3: Selector switch in connection with rotary switch 5 and LED-Display 7
¾ time gas preflow
0s…3s
¾ duration of the positive ignition pulse
2ms…100ms
¾ start current
5A…320A/420A
¾ time up slope
0s…2s
¾ welding current l (main curr)
5A…320A/420A
¾ time l (for curr l in pulse slow)
0,01s…2,5s in DC
0,05s..2,5s in AC
pulse frequency (in pulse fast)
51Hz…5kHz in DC
¾ time down slope
0s…20s
¾ final current
5A…320A/420A
¾ time spot w.( using spot welding)
0,1s…2,5s
¾ time gas postflow
0s…25s
4: Selector switch in connection with rotary switch 6 and LED-Display 8
¾ TIG-electrode diameter in mm
1,0/1,6/2,4/3,2/4,0/4,8
is limitating the max. amperage
in order to protect the TIG-electrode
¾ AC-frequency
50…200Hz*
a higher frequency gives a more
stable arc welding in lower amperages
¾ AC-balance (% plus pole at TIG-torch)
9%..91% 50Hz*
reduced in higher frequencies in order
to maintain the stability of the
welding arc:
36%..64% 200Hz*
19
¾ Time 2 (for current in pulse slow)
0,01s…2,5s in DC
0,05s…2,5s in AC*
10%…100% of curr l
¾ Welding current 2
¾ Voltage indication; hold-function after the weld
¾ Time hotstart
0s..l,5s
to assure ignition welding electrodes
¾ Current hotstart
10%..200% of curr l
¾ Arc Force
100%..250% of curr l
increases the welding current in order
to avoid adherence of the electrode. Using
cellulose electrodes, setting in pos max. is required.
The LED-display 7 resp. 8 indicates a non-valid parameter set by the selector switch and that is not
used for the welding process, for ex. AC-frequency when TIG-DC is selected.
* : Only mounted in the TIG-series Insquare W 300 AC/DC, W 420 AC/DC and W 600 AC/DC,
otherwise "no AC" is indicated on the LED-displays 7 and 8.
9: LED-indicator
Before the weld, the indicator is determined by the Position of the selector switch 3, during the
weld the indicator shows the Status quo of the welding process.
10: HOLD-indicator
When the hold-indicator is enlighted, the LED-display 7 shows the last value (amps) provided
that the selector switch 3 is set on pos curr 1. The LED-display 8 is indicating the welding voltage
(volts) provided that the selector 4 is set on pos voltage. After a few seconds, both LEDs switch
back to the preselected values.
11: Botton PROGRAM-NO.
Storage and activation of welding programs (adjustings of the parameters at the front panel)
12: LED-indications
Mains On
Over loading
Failure: Overloading or
mains overvoltage or
mains undervoltage or
waterpressure missing (beaking) or
activation of the protection device (Urms<48V) or
using a robot open emergency-OFF circuit of the welding unit.
Urms<48V: Indication of the protection device for no load
voltage without risk.
13: Botton-Test of the protection device (S-symbol)- only mounted in the AC-version
With this welding unit ace. norms EN 60974-1 and VDE 0544 welding jobs in confined areas can
be realised as a standard.
The correct function of the protection device can be checked as following:
- main switch ON
- the LED-indicator Urms<48V is enlighted
- do not use torch trigger. Do not touch torch electrode
or stick electrode clamped in the electrode holder
20
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
¾ Off
¾ Pulse slow (in DC and AC)
During time 1 flows curr 1 (selector switch 3), during
time 2 flows curr 2 (selector switch 4) ^
¾ Pulse fast (only in DC)
The fast pulse makes the DC-arc narrow.
The pulse frequency (selector switch 3) determines the
change from welding curr 1 to 2 with
a time share of 50% respectively.
¾ Spot welding
Spot welding time see selector switch 3;
internally times for the slopes are set to 0 sec. As soon as the welding current flows after
pushing the trigger, the spot welding time is counting. After this time has passed, the welding
process is automatically finished. A new start only is possible after releasing and pushing again
the trigger.
15: Selector switch ignition
¾ High frequency OFF
¾ HF ignition: The arc will be started by a high frequency ignition generator. The
tungsten electrode may not touch the work piece at the ignition process.
¾ Lift Arc ignition: Lift arc ignition is need, when TIG welding is performed close to
sensitive electronic devices. Touch down the tungsten electrode to the work piece, press
down the torch trigger and lift the electrode. While the tungsten electrode touches the
work piece a minimum current is activated in order to prevent the electrode from
sticking to the work piece.
16: Selector switch for welding current
¾ Adjusting on the front panel: current 1
(selector switch 3)
¾ Adjusting on the torch (option)
¾ Adjusting on the manual remote control. The value of curr 1 (selector switch 3) determines
the max. value of the variable resistor on the manual remote control turning it to the max. right.
¾ Adjusting on the foot pedal
The value of curr 1 (selector switch 3) determines the max. value of the foot pedal when it
is completely pushed down.
17: Selector switch operation mode
¾ 4-stroke-mode
1.stroke: push down the torch trigger :
ignition of the arc, the start current is flowing
2.stroke: release of the torch trigger:
the current slopes up to the selected value of current 1
in the period selected by the timer
21
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. If in the 3. stroke during the down slope the trigger is released, the current is switched off
as well.
¾ 4-stroke-mode with switching over on the torch
This mode works likes the standard-4-stroke (see above).
The difference is that during the welding process a switching
over from current 1 to current 2 can be effected by pushing down
the trigger. If the trigger is pushed longer than 0,5 sec., the machine
switches over to the 3. stroke and the down slope starts.
¾ 2-stroke-mode
1.stroke: after the pushing down of the trigger, and after the end of the gas preflow time, the
current slopes up from the start current to the welding current 1 in the period
selected by the timer.
2.stroke: release of the trigger: the current slopes down on the value of the final current in the
period selected by the timer and is switched off. The gas postflow time starts.
¾ TEST GAS
The gas valve is opened for 1 min. The upper LED-display 7 shows GAS. The lower LEDdisplay 8 shows the remaining time in seconds.
¾ TEST/PROG
When the selector switch is put in this position, the LED HOLD is always beaking.
A currentless check of the TIG-process and a supervision of the selected currents is possible.
Therefor, the selector switch 3 has to be put on pos STROM/current 1. Only in 4-stroke-mode.
After pushing down the torch trigger, the current (upper LED-display 7) remains on the
START CURRENT (1. stroke) and slopes up to current 1 (2. stroke) in the seleccted time after
Releasing the trigger.
If an existing 2nd. trigger is pushed down, the current switches to the value of current 2.
During a further actuation of the trigger, the current slopes down or from current 1 or from
current 2 in the selected time to the end current (3 stroke).
If now the trigger is released (4. stroke), the process is finished.
¾ Storage Functions
1 Automatic storage of the welding parameters used during the last welding process:
All parameters selected by the selector switches 3 and 4 and the rotary switches 5 and 6 are
automatically stored after the last welding process and after the HOLD-time has passed. These
values are again available immediately after the generator has been switched on again. Both, TIG
and electrode welding parameters (selector switch 2) can be stored in a separate program.
2 Program storage
After the selection of the welding process (selector switch 2), the parameters (selector switch 3
and 4, and the rotary switches 5 and 6), the selector switch operation mode 17, is set on
pos. TEST/PROG.
22
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. ⇒ free: .…; electrode DC: Edc; TIG DC: tdc; TIG AC: tAC; electrode AC: EAC.
The storage of the welding process only serves to inform the operator using the different
programs. The welding process, however, is always determined by selector switch 2.
If the botton PROGRAMM-NR is pushed down longer than 3 sec., the storage of the select
program place is effected, confirmed by a short extinction of the LED-display.
20 programs are available, indicated by n. 1..20. The indication NO means no program
selection; the parameters inside the working storage keep unchanged.
3 Program Recall
Selector switch 17 on 4-stroke or 4-stroke with 2 currents or 2-stroke. Push down botton
PROGRAMM-NR. 11 and select the desired program by the rotary switch. Indication of the
progr.-no on the lower LED-display 8. At the same time the LED-display 7 indicates the
availability of the different programs (see above).
If the botton PROGRAMM-NR. is pushed down longer than 1,5 sec., the selected program is
loaded according the programmed.welding mode (TIG or electrode), confirmed by a short
extinction of the LED-display. After the welding with a loaded program the program-no, as well is
stored. If the generator is switched OFF and ON again, the recent loaded program is immediately
available without any further intervention.
4 Storage of a modified program
If a program is stored as described in item 3, its modified parameters are automatically
maintained after each weld. They are available after every switch ON of the generator, as
far as no other program is recalled. If it is desired to store a modified program, precede as
described in item 2.
9.
TIG welding
9th1 preparing-values at DC welding
- standard values for the TIG manual welding in level position of special alloy steels, direct
current minus polarity kind of current of 0,6, - 16 mm material thickness
Mate- Weld- Seamrial- form distance
in mm
thicknes in
mm
0,6
0,8
1,0
1,5
2,0
2,5
3,0
4,0
I
I
I
I
I
I
I
I
6,0
I
12,0
I
Vshaping
Xshaping
Xshaping
Number
Midle
welding- of layers
current
in A
20-30
40
45
50
80-100
100-130
140
180
Welding- Wolfram- Argon- Argon
tip
weldingelectrode
rod
gas
grey
in mm
l/min.
in mm
1
1
1
1
1
1
two sided
1
1,6
1,6
1,6
1,6
2,4
2,4
2,4
2,4
1,0
1,0
1,0
1,6
1,6
1,6
2,4
3,2
4
4
4
4-6
6-8
6-8
8
8-10
5
5
5
6
7
7
7
10
220
2
3,2
3,2
8-10
10
260
4
4,0
3,2
10-12
10
23
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.
9th2 preparing-values at AC welding
- standard values for the TIG manual welding in level position of aluminium ,
alternating current kind of current of 1,0 - 12 mm material thickness
Welding- Wolfram- Argon- Argon
tip
weldingrod
electrode
gas
in mm
grey
l/min.
in mm
Mate- Weld- Seamrial- form distance
in mm
thicknes in
mm
Number
Midle
welding- of layers
current
in A
0,8
1,0
2,0
3,0
4,0
5,0
I
I
I
I
V
V
35
50
95
140
185
235
1
1
1
1
1
2
1,6
1,6
2,4
2,4
3,2
3,2
1,0
1,6
2,4
2,4
3,2
3,2
4
4
6-8
8
8-10
8-10
5
5
7
7
10
10
6,0
V
280
2
4,0
3,2
8-10
12
8,0
12,0
V
V
300
300
2
2
4,0
4,0/4,8
4,0
4,0/4,8
8-10
10-12
12
12
V
Vshaping
Xshaping
1 bis 3
1 bis 3.
Setting of the indicated values as commented under point 9.1.
Warning! Attention
High frequency ignition voltage (HF) and no load voltage are connected to the
Stick electrode connector during TIG welding operation! Disconnect stick
electrode welding cable always when TIG welding is done.
10. MMA stick electrode –welding
To the stick electrode -welding set the rotary switch (1) into the lowest position.
Caution:
Open-circuit voltage fits at the connection sockets "welding electric circuit".
The unit has following functions in stick electrode-welding mode (MMA)
¾ current adjustment (Arc Force):
Increase in current while push the electrode into the welding bath.
Following attitudes are regarded as standard values:
Rutile-electrodes: 120 %
Basic Electrodes: 150 %
Cellulose-electrodes: 250 %
24
If nevertheless should burn the electrode, the welding current is reduced to a minimum.
An igniting of the electrode is prevented thus.
¾ Electrode high start (Hot Start):
To secure ignition a higher start current is established for a short time.
¾ Anti Stick function:
While sticking the electrode the current is reduced immediately onto the minimum
value. New start after the peeling first after a short delay.
10th1 Standard values for the metal arc welding
Setting of the welding current according to electrode model and diameter. Rule-of-thumb:
Electrode diameter
(mm)
welding current (A)
2,0
2,5
3,25
4,0
5,0
6,0
40-80
60-100
90-150
140-180
170-240
250-300
Read and respect information, for example polarity,
respective electrode supplier.
11. Display
From software :
E-PROM MTC TIGF V4.2
E-PROM MTC TIGA V4.2
or higher
or higher
additional ERROR functions are integrated:
code
on the LED
display (5)
Err
ULO
Err
UHI
Err
H2O
Err
AC
Err
GAS
Failure
phase missing
mains-low voltage
Mains-overvoltage
check water in the
water cooling unit
failure in AC-generator
(+15V or -15V on pcb
ME-WS-1.X, or bad contact
of flat cable to powermodul of
AC-generator)
in connection with PT10W:
too low gas pressure of
pilotgas or protective gas
25
from the instructions of the
12. Trouble Shooting
Errors
Causes / helps
Green LED (mains) is off after switching ON - at least one phase missing
- mains connector wrongly connected
the unit
- 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
is flashing
TIG: no OCV after pressing the torch trigger - torch trigger cable not plugged in at the
rear side of the unit
- time of pregasflow too high
- selector (16)put on position foot pedal
- selector (17)on position TEST / PROG
TIG: no HF
- selector (15) on position HF
defective fuse F6 at the control transformator
TIG: insufficient HF
- electrode cable plugged in
Attention! HF and OCV/welding voltage
in TIG mode at the socket for MMA welding
(losses of HF due to plugged in cable)
TIG: no welding current
- workpiece cable plugged in at the socket for
MMA welding
Electrode: no OCV and green LED „HOLD“ - selector (17) on pos. TEST / PROG
is flashing
Electrode sticks in the welding bath
- too low setting of Arc Force
Red LED failure is shortly ON
Yellow LED overtemperature and
Red LED failure are ON
- mains low voltage or to high voltage
- overtemperature of transformer or cooling
device: let the unit cool down
Red LED failure is ON and green LED
URMS <48V is OFF
- supervision device activated:
main switch OFF and after >3s again ON
Red LED failure is ON
-continous excess of current at the primary
side: main switch OFF and after >3s ON
again
26
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. Maintenance and Accident Prevention
The maintenance of the welding machine consists of a regular cleaning and inspection. It
depends on the environment of the working area and the working hours.
The machine should be cleaned in regular intervals to guarantee a proper operation. The
length of the cleaning interval depends on the operation time, surrounding atmosphere etc.
ATTENTION:
Before opening the welding machine, make sure
that it is disconnected from the mains supply. Wait for
components to be sufficiently cooled down !
15. Inspection
Check the unit whether all wires, terminals, sockets are ok. If necessary exchange them.
Check torch hose and connectors and if necessary exchange them.
As cooling liquid use only our MKF part no. 107.822. The tank has got a capacity of appr.
2,0 liters without torch. Losses of waters (mostly due to torch changes) have to be
compensated otherwise operation will be interrupted.
If too much water is missing, the pump must eventually deareated. Follow the advises sticked
on. If the water is too dirty renew it completely.
It is advisable to clean the unit in regular period. After inspection screw on the housing plates
again.
27
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:
DC range:
AC range:
Electrodes:
Weight:
water cooled
450 A, 60 % duty cycle
400 A, 60 % duty cycle
1.0 – 4.0 mm ∅
320 g (without cable sassembly)
28
TIG Hand Welding Torch, Model TH 450 W, water cooled
with Merkle TCG connector or with Euro connector
29
TIG Hand Welding Torch, Model TH 450 W, water cooled
Pos.
Description
Part No._
TIG hand welding torch
model TH 450 W, 4 m
with Merkle TCG connector
108.274
TIG hand welding torch
model TH 450 W, 8 m
with Merkle TCG connector
108.276
TIG hand welding torch
model TH 450 W, 8 m with Merkle
TCG connector and potentiometer
108.278
With Euro connector:
TIG hand welding torch
model TH 450 W, 4 m
with Euro connector
104.402
TIG hand welding torch
model TH 450 W-EURO, 8 m
with Euro connector
104.408
TIG hand welding torch
model TH 450 W-EURO, 8 m with Euro
connector and potentiometer
104.409
Standard equipment: 3,2 mm, ceramic 12.5
Spare parts and consumables:
3.1
3.2
3.3
3.4
3.5
8
9.1
Tungsten-electrode, grey
1.0 x 175 mm
Tungsten-electrode, grey
1.6 x 175 mm
Tungsten-electrode, grey
2.4 x 175 mm
Tungsten-electrode, grey
3.2 x 175 mm
Tungsten-electrode, grey
4.0 x 175 mm
Torch neck TH 450 W
Back cap "quick TIG" 1.0 mm, long
TH 170/250 G, TH 450 W
min 10 pcs
013.0.0111
min 10 pcs
013.0.0112
min 10 pcs
013.0.0113
min 10 pcs
013.0.0114
min 10 pcs
013.0.0115
104.248
106.850
30
Pos.
Description
Part No._
9.2
Back cap "quick TIG" 1.6 mm, long
TH 170/250 G, TH 450 W
Back cap "quick TIG" 2.4 mm, long
TH 170/250 G, TH 450 W
Back cap "quick TIG" 3.2 mm, long
TH 170/250 G, TH 450 W
Back cap "quick TIG" 4.0 mm, long
TH 450 W
Back cap "quick TIG" 1.0 mm, short
TH 170/250 G, TH/TM 450 W
Back cap "quick TIG" 1.6 mm, short
TH 170/250 G, TH/TM 450 W
Back cap "quick TIG" 2.4 mm, short
TH 170/250 G, TH/TM 450 W
Back cap "quick TIG" 3.2 mm, short
TH 170/250 G, TH/TM 450 W
Back cap "quick TIG" 4.0 mm, short
TH/TM 450 W
O ring 9 x 1.5
Ceramic nozzle 6.5
TH 170/250 G, TH 450 W
Ceramic nozzle 8.0
TH 170/250 G, TH 450 W
Ceramic nozzle 10.0
TH 170/250 G, TH 450 W
Ceramic nozzle 12.5
TH 170/250 G, TH 450 W
Ceramic nozzle 15.0
TH 170/250 G, TH 450 W
Adjustement wheel incl.
potentiometer for TH 250/450/600 W
Handle TIG torch, right and left
side (delivered without ball joint)
pc board for TIG double button
switch (for torch with ball joint)
Switch button (red)
for TIG torch with ball joint
Handle TIG torch, right and left
side (delivered without ball joint)
Kinking protection for TIG handle
O-ring 8 x 1.6
Merkle TCG connector plug
(water cooled) incl. rubber housing
and 2 o-rings
Gas hose 4.5 x 1.3 high flexible
Coupling nipple no. 3305
Round plug 5-pole for TIG torch
(standard)
Gas hose 4.5 x 1.3 high flexible
106.854
9.3
9.4
9.5
10.1
10.2
10.3
10.4
10.5
11
12.1
12.2
12.3
12.4
12.5
29
31
33
34
35
37
43
44
45
46
47
48/49
106.856
106.858
106.860
107.684
107.686
107.688
107.690
107.691
min 10 pcs
min 10 pcs
022.1.0704
104.260
min 10 pcs
104.262
min 10 pcs
104.264
min 10 pcs
104.266
min 10 pcs
104.268
108.354
108.368
107.992
107.994
107.988
min 10 pcs
107.998
103.544
109.556
107.972
025.1.0400
021.1.0380
107.972
31
Pos.
Description
Part No._
50.1 Power cable TH 450/250 W, 4m, 10qmm
for torches with Merkle TCG and Euro connector
50.2 Power cable TH 450/250 W, 8m, 10qmm
for torches with Merkle TCG and Euro connector
51.1 Control cable 3 x 0.5 LiYY
min 50 m
no shield
51.1 Control cable 3 x 0.5 LiYY
no shield
51.2 Control cable 5 x 0.5 LiYY
min 50 m
no shield
51.2 Control cable 5 x 0.5 LiYY
no shield
54
Protection hose leather,
min 50 m
26 mm, black
54
Protection hose leather,
26 mm, black
58.1 Cable assembly TH 450/250 W, 4 m
10 qmm, Merkle TCG connector
(control cable 3 x 1.5)
58.2 Cable assembly TH 450/250 W, 8 m
10 qmm, Merkle TCG connector
(control cable 3 x 1.5)
58.3 Cable assembly TH 450/250 W, 8 m
10 qmm, Merkle TCG connector
(control cable 5 x 1.5)
Cable assembly with Euro connector:
70
Euro-connector for TIG torches,
water cooled
71
Euro adapter nut
72
Kinking-protection, intake
73
Spring for kinking protection
Euro connector, water cooled
75
Gas hose 4.5 x 1.3 high flexible
76
Coupling nipple no. 3305
77
Round plug 5-pole for TIG torch
(standard)
79.1 Cable assembly TH/TM 450/250 W, 4 m
10 qmm, Euro connector,
(control cable 3 x 1.5)
79.2 Cable assembly TH/TM 450/250 W, 8 m
10 qmm, Euro connector,
(control cable 3 x 1.5)
79.3 Cable assembly TH 450/250 W, 8 m
10 qmm, Euro connector,
for torches with potentiometer
(control cable 5 x 1.5)
32
104.378
104.379
107.646
107.646
107.242
107.242
107.650
107.650
107.652
107.660
107.664
013.4.0061
025.1.0300
025.1.0100
022.1.1579
107.972
025.1.0400
021.1.0380
108.362
108.364
108.366
16th2 TIG Hand Welding Torch, Model TH 600 W, water cooled,
with Euro connector
Technical data:
Cooling:
DC range:
AC range:
Electrodes:
Weight:
water cooled
600 A, 60 % duty cycle
500 A, 60 % duty cycle
2.4 – 4.8 mm ∅
360 g (without cable assembly)
33
TIG Hand Welding Torch, Model TH 600 W, water cooled,
with Euro connector
34
TIG Hand Welding Torch, Model TH 600 W, water cooled
Pos.
Description
Part No._
TIG hand welding torch
model TH 600 W, 8 m
with Euro connector
104.410
TIG hand welding torch
model TH 600 W, 8 m with Euro
connector and potentiometer
104.416
Standard equipment: 4.0 mm, ceramic 13
Spare parts and consumables:
1.1
1.2
1.3
1.4
2.1
2.2
2.3
2.4
3.1
3.2
3.3
3.4
4
5.1
5.2
5.3
7
29
31
Back cap "quick TIG" 2.4 mm, long
TH 600 W
Back cap "quick TIG" 3.2 mm, long
TH 600 W
Back cap "quick TIG" 4.0 mm, long
TH 600 W
Back cap "quick TIG" 4.8 mm, long
TH 600 W
Back cap "quick TIG" 2.4 mm, short
TH 600 W
Back cap "quick TIG" 3.2 mm, short
TH 600 W
Back cap "quick TIG" 4.0 mm, short
TH 600 W
Back cap "quick TIG" 4.8 mm, short
TH 600 W
Tungsten-electrode, grey
2.4 x 175 mm
Tungsten-electrode, grey
3.2 x 175 mm
Tungsten-electrode, grey
4.0 x 175 mm
Tungsten-electrode, grey
4.8 x 175 mm
Torch neck TH 600 W
Ceramic nozzle 10.0, TH 600 W
Ceramic nozzle 13.0, TH 600 W
Ceramic nozzle 16.0, TH 600 W
O ring 11 x 2.5
Adjustement wheel incl.
potentiometer for TH 250/450/600 W
Regelrad komplett mit Potentiometer
Handle TIG torch, right and left
side (delivered without ball joint)
107.722
107.724
107.726
107.728
107.734
107.736
107.738
107.740
min 10 pcs
013.0.0113
min 10 pcs
013.0.0114
min 10 pcs
013.0.0115
min 10 pcs
013.0.0116
min 10 pcs
104.270
104.300
104.302
104.304
050.1.1829
108.354
108.368
35
Pos.
Description
Part No._
33
pc board for TIG double button
switch (for torch with ball joint)
Switch button (red)
for TIG torch with ball joint
Handle TIG torch, right and left
side (delivered without ball joint)
Kinking protection for TIG handle
Gas hose 4.5 x 1.3 high flexible
Power cable TH 600 W, 8m, 16 qmm
Control cable 3 x 0.5 LiYY
no shield
Control cable 3 x 0.5 LiYY
no shield
Control cable 5 x 0.5 LiYY
no shield
Control cable 5 x 0.5 LiYY
no shield
Protection hose leather,
26 mm, black
Protection hose leather,
26 mm, black
Cable assembly TH 600 W, 8 m
16 qmm, Euro connector
Cable assembly TH 600 W, 8 m
16 qmm, Euro connector
for torch with potentiometer
Euro-connector for TIG torches,
water cooled
Euro adapter nut
Kinking-protection, intake
Spring for kinking protection
Euro connector, water cooled
Gas hose 4.5 x 1.3 high flexible
Coupling nipple no. 3305
Round plug 5-pole for TIG torch
(standard)
107.992
34
35
37
48/49
50
51.1
51.1
51.2
51.2
54
54
58.1
58.2
70
71
72
73
75
76
77
107.994
107.988
min 50 m
107.998
107.972
107.752
107.646
107.646
min 50 m
107.242
107.242
min 50 m
107.650
107.650
107.744
107.746
013.4.0061
025.1.0300
025.1.0100
022.1.1579
107.972
025.1.0400
021.1.0380
36
17. Spare parts and wiring diagram
17th1 Spare part list TIG Insquare W 300/420 DC
electr.
02.04.2004
part no.
description
A0
A1
A2
A3
A7
A9
A10
A11
A12
A13
A14
A15
line filter ME-NF400/2.5
pc -board ME-I-PG-1.1
pc -board ME-I-PI-1.0
pc -board Pc-board ME-I-SD-1.1B
pc -board ME-I-RC-1.1
LEM-converter HTA 400 S
ignition generator SIG 3.7
pc -board ME-MTC-1.2
pc -board ME-MTC/T 1.5
pc -board ME-BT-1.5
pc -board ME-TF-1.2
pc -board Pc-board ME-EMV-3.1
102.279
003.0.0001
003.0.0002
003.0.0003
003.0.0004
010.0.1615
020.1.1640
003.1.0042
003.0.0008
003.0.0009
003.0.0012
102.281
C1
capacitor 0,1 µF/1000V
001.0.0415
F1
F1
F3
F4
F6
F7
F8
fuse 4 A slow 6,3x32 mm
fuse 4 A slow 6,3x32 mm
fuse 10 A slow 5x20 mm
fuse 1 A slow 5x20 mm
membran switch 0,5 bar
termical switch 80°C opend
overcurrent switch 1,4 A
003.0.1251
003.0.1251
003.0.1199
003.0.1212
004.0.0204
001.0.0406
003.0.0320
K1
relais 48V (option automatic welding)
relais socket
010.0.1961
010.0.1962
L1
choke (ferrit)
020.1.1661
M1
M2
M3
M4
M5
fan 230 V-AC at the Inverter
fan 230 V-AC at the Inverter
fan 230 V-AC at the water cooler unit
fan 230 V-AC at the water cooler unit
waterpump 230V 50Hz 0,12 kW
001.0.1323
001.0.1323
001.0.1323
001.0.1323
004.0.0530
Q1
main switch HLT 40
001.0.0014
R1
R2
R3
R4
R5
R6
resistor 330 Ω/50W
resistor 330 Ω/50W
resistor 0,02 Ω/50W
resistor 39 Ω/50W
resistor 330 Ω/50W
NTC resistor 100 kΩ (transformer inside)
030.0.4583
030.0.4583
030.0.4580
030.0.4584
030.0.4583
010.0.1934
37
electr.
description
part no.
R7
NTC resistor 47 kΩ (prim. IGBT)
010.0.1933
S1
T1
T2
T3
T4
selector (option automatic welding)
main transformer with choke
control transformer EI 120/73,7 950VA
converter
converter
003.0.0900
020.1.1661
003.0.0242
020.1.1124
020.1.1124
V1
V2
V3
V4
V5
V6
V7
V8
V9
V10
sec. rectifier-modul
sec. rectifier-modul
sec. rectifier-modul
sec. rectifier-modul
sec. rectifier-modul
sec. rectifier-modul
prim. rectifier
thyristor modul
prim. IGBT
prim. IGBT
001.0.0287
001.0.0287
001.0.0287
001.0.0287
001.0.0287
001.0.0287
001.0.0285
001.0.0286
001.0.0173
001.0.0173
X1
X2
X3
X5
X6
X7
TIG euro connector
bush 70/95mm² 500A
bush 70/95mm² 500A
5-pol.socket (torch switch)
10-pol. socket (option: remote control)
10-pol. plug (acessories)
strain relief (acessories)
connector 6-pol. pin (Option automatic welding)
025.1.1685
001.0.1102
001.0.1102
021.1.0394
021.1.0386
021.1.0383
021.1.0388
015.0.0102
Y1
valve 42V/AC
002.0.1602
Z1
protection circuit
003.0.0334
crimpcontakt (accessories)
016.0.0140
17th2 Wiring diagram INS 300-420 DC
38
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Änderung
T1 T2 T3
L 1 ´L 2 ´L 3 ´
+SQ
-A15
sw
15.11.99
Datum
-R1
-R2
Konrad
Name
bl
bl
br
bl
ME-EMV-3.0
L1 L2 L3 PE
sw
sw
Plotdatum: 05.06.03
a
b
c
d
+SQ
-Q1
sw
L1 L2 L3
sw
sw
1
2
1
2
1
2
1
2
3
rt
4
4
1
F3
F2
F1
L3
L2
L1
-A1
Konrad
Siegner
gepr. 21.02.00
Name
ME-I-PG-1.1
Prim.DC
gn
-
-
+
-
-
-
+
10
rt
-R3
-V8
-V7
+
U<
rt
X2
01.06.99
Datum
bl
+SQ-T2:0V/2.1
+SQ-T2:400V/2.1
+ U>
U>Umax U<Umin
0,2A
0,2A
0,2A
X4
-
2
1
3
rt
br
gr
X1
+
Überst./ rt
X 3 over current
2
L3´
L2´
1
+SQ
-A0
gez.
L3
L2
PE
ME-NF400/2.5
-T1
-T3
7
bl
bl
bl
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
5
6
X1
4
3
2
3
1
1
2
4
2
1
-V5
-V4
3
4
3
4
-A10
Schweißstromkreis
ME-I-RC-1.1
5
3
1
1
2
4
2
6
-R4
-C1
-R5
3
4
3
4
1
+SQ
-Z1
-X8
+SQ
-A9
rt
bl
1 2 3 4
bl
ge
gn
rt
1 2 3 4
7
24
23
Auftragsnr.
Zeichnungsnr.
INSQUARE W300/420DC
Projektbez.
1
2
-V6
1
2
-V3
42V~
Zündgerät
COIL
-V2
-L1
-V1
X3
16
1
-A2
ME-I-PI-1.0
T-Prim.
- -V9
+
+
-- V 1 0
T-Prim.
8
-A7
rt
Erdungsschraube
br
PE
br
L1 L2 L3
4
br
3
br
2
br
3PH-400V/50Hz/PE
br
1
rt
+SQ
-T4
rt
bl
-
+
-
5
Blatt
1
Bl.
=
+ INV
Brenner/
torch
+SQ
-X1
Werkstück/
work piece
+SQ
-X3
+INV-A3-X8:2/2.6
+INV-A3-X8:1/2.6
Elektrode/
stick electrode
+SQ
-X2
+SQ-T2:w3-0V/2.1
+INV-A3-X8:6/2.6
+INV-A3-X10:4/2.3
+INV-A3-X10:3/2.3
+INV-A3-X10:2/2.3
+INV-A3-X10:1/2.3
+INV-A3-X7:4
+INV-A3-X7:1/2.5
+INV-A3-X12/2.4
+INV-A3-X4/2.6
8
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Änderung
0/230V
Datum
4A
w1
-F3
Name
22
23
w5-9V
w5-0V
16
w10-9V
rt
gn
ge
bl
w11-0V
19
18
15
w9-0V
w11-9V
14
w9-18V
17
13
w8-0V
w10-0V
12
w8-18V
w7-0V
w7-18V
w6-0V
w6-9V
21
20
w3-37V
w3-42V
w4-18V
w4-0V
10A w3-0V
U
+INV
-R6
19
18
19
Siegner
gepr. 21.02.00
Name
+INV-R4/1.6
5
4
3
sw
sw
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
X5
ge
rt
ge
rt
X2
X10
X6
1
gn
16
ge
rt
LT
-15V
gn
Reg.
Spr.
PU500
I>0
intern
ext
Res
intern
3
4
+
3
1
2
X7
U ist
Istat.
Idyn.
X1
Störung/failure
1
Untersp./under voltage
Übersp./over voltage
gn
gn
rt
rt
rt
ge
I>0
Res.
Gas
Erdungsschraube
X9
X14
X8
6
5
4
3
2
1
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
10
1
27
6
5
27
27
25
30
6
4
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
24
-F8
Steuerstromkreis
1
-
Wasserp./
pump
Lüfter/
fan
RES
I>0
HF
Gas
rt
rt
rt
rt
rt
MAG TIG
I>0
Start
POL
T>50C°
rt
rt
rt
X4
34
rt
25
Übertemp./over temp.
5
WD.fehlt/no water pressure
ME-I-SD-1.1
+15V
gn
bl
UeT
LI
UeI
+5V
gn
Idyn
rt
+INV
-A3
+15VP PWM-ON Istat
gn
X12
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
1
2
6
bl
7
bl
rt
8
rt
9
1
2
3
4
1
2
3
4
5
6
7
8
+SQ-A11-X1:1/3.3
+SQ-A11-X1:2/3.3
+SQ-A11-X1:3/3.3
+INV-X8:1/1.7
Konrad
Datum
+INV-A10:42V~/1.6
+SQ-A11-X1:4/3.3
25
01.06.99
gez.
NTC-Trafo
U
+INV
-R7
NTC-IGBT
+INV
-F7
Gleichrichter/
rectifier
+SQ-A9-X1:1/1.7
+SQ-A9-X1:2/1.7
+SQ-A9-X1:3/1.7
+SQ-A9-X1:4/1.7
PE
w12-0V
w12-42V 1A
-F2
-F4
w2-0V
w2-9V
sw1/sw2
bn 0V
4A
-F1
28 0/230V
27
230V
gr 400V
Plotdatum: 05.06.03
a
b
c
d
Erdungsschraube
+SQ-A0:L3´/1.2
+INV-A3-X9:1/2.6
+INV-A3-X9:2/2.6
+SQ-A0:L2´/1.2
1A
5A
1A
1A
2A
1A
1A
1A
1A
1A
4
Lüfter/fan
3
Wasserp./pump
2
5
1
2
4
3
24
M
Auftragsnr.
+SQ-T4/1.8
+SQ-T4/1.8
+INV-A1-X2/1.3
+SQ-A11-X2/3.5
M
Pumpe/
pump
PE
M
Zeichnungsnr.
+INV
-M1
M
-M3
Lüfter/ PE
fan
Lüfter/ PE
fan
P
+OP1-X7:2/3.1
+OP1-X7:1/3.1
Blatt
=
+ SQ
M
5
Bl.
2
PE
+INV
-X9
+INV-A10:42V~/1.6
24
INSQUARE W300/420DC
PE
-M5
+SQ-T2:230V/2.1
PE
+INV
-M2
8
+INV-A2-X3/1.5
-M4
-F6
29
25
24
23
bl
rt
7
+SQ-T2:0/230V/2.1
24
3
-X4
5
1
2
4
3
27
28
3
-Y1
Projektbez.
26
bl
-T2
br
1
schw
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Not-Aus/emergency stop
Not-Aus/emergency stop
3
5
6
7
Datum
Plotdatum: 05.06.03
a
b
c
d
4
Änderung
2
1
5
4
3
2
4
3
2
1
4
3
2
1
Siegner
.8
gepr. 21.02.00
Name
12
11
10
.7
6
5
5
9
7
6
6
20
1
2
3
4
1
8
1
2
3
4
7
1
2
3
4
24
7
Konrad
Datum
4
3
8
2
7
1
6
5
23
22
21
20
A1
A2
+OP1
-K1
01.06.99
gez.
+SQ-T2:w5-0V/2.1
+SQ-T2:w5-9V/2.1
+SQ-T2:w4-0V/2.1
+SQ-T2:w4-18V/2.1
3 Windungen/
3 turns
Name
2
3
26
25
10
9
Ferritring/
feritt ring
4 Windungen/
4 turns
machine welding connection
1
2
Hand/Automatik
Schweissen ein/welding on
Schweissen ein/welding on
Lichtbogen I>0/arc ok
Lichtbogen I>0/arc ok
+OP1
Option:
-S1
Automatenanschluß/
6
5
4
3
2
1
+OP1
-X7
X6
16
1
2
ge
3
X7
4
3
sw
5
+SQ-T2:w3-42V/2.1
+SQ-T2:w3-0V/2.1
+INV-A3-X8:8/2.6
+INV-A3-X8:7/2.6
6
5
X9
X4
B
A
GND
X3
Energy
1
1 9
4
X8
sw
1
ge
X12
4
3
2
1
4
3
2
1
X10
5
5
-A12
1
4 3 2 1
X2
6
6
34
7
2
1
7
5
ws
ws
+INV-W7
JP2
1
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
TEST
K
I
X1
H
E
E
-X6
X3
F
G
D
D
C
C
S
B
B
-A13
E
A
A
A
+SQ-A14-X1/4.5
+SQ-A14-X2/4.6
ge
4
X5
7
1
1
31
.3
+OP1
-K1
1
2
sw
2
3
BT. Poti
2
2
torch
switch
2
BT2
3
3
X2
4
4
oder/
or
torch
switch
1
BT1
1
1
31
9
5
Zeichnungsnr.
INSQUARE W300/420DC
Auftragsnr.
8
S
4
gn
.3
+OP1
-K1
gn
12
8
5
Blatt
=
+ SQ
Brenner mit Doppeltaster
oder mit Brennerpoti/
torch with 2 button
or with torch poti
-X5
5
ME-BT-1.5
Option:
Automatenanschluß/
machine welding connection
Projektbez.
+OP1-A14-X3:1/4.3
+INV-A3-X6:7/2.3
+INV-A3-X6:8/2.3
+OP1-A14-X3:2/4.3
Fußfernregler/
foot remote control
FT
+INV-A3-X1/2.5
TOUT
TIN
AGND
Poti Fern/remote control
Fußt/switch foot pedal
TIG/BT2/torch switch 2
REF50
X4
6
BT/torch switch
Steuerstromkreis
1
X15
ME-MTC/T-1.5
X1
Anpassung
Spannungsanzeige/
adjust voltage
display
X13
X11
1
+INV-W6
1
X5
10
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
26
X14
ME-MTC-1.2
-A11
Korrektur/trim
Taster Draht/button wire feed
+5V
X1
1
3
3
3
1
1
GND
1
3
Bl.
E
A
Brennerpoti/torch poti
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Änderung
Datum
HOLD
gn
Plotdatum: 05.06.03
a
b
c
d
<48V
RMS
S TEST
U
gn
Störung/
failure
rt
Übertemperatur/
overtemp.
ge
NETZ/
main
gn
1
Name
Siegner
gepr. 21.02.00
Name
Konrad
Datum
Hz
S
A
kHz
Hz
S
01.06.99
gez.
PROGRAMM-NR.
-A14
V
A
3
1
1
ANSTIEG/upslope
X1
TIG-ELEKTRODE O mm
AC FREQUENZ/frequency
AC BALANCE + (%)
ZEIT t2/time t2
STROM I2/current I2
GAS:VORSTRÖMEN/preflow
ZÜNDIMPULS/ingniton pulse
1
16
DISPLAY: SPANNUNG/voltage
GAS:NACHSTRÖMEN/postflow
X2
1
Frontplatine
26
STROMNACHREGELUNG/arc force
HOTSTART-STROM/current
HOTSTART-ZEIT/timer
6
1
JP8
2
Plasma
3
4
JP7
+
+
+
-
5
TIG
JP6
6
300A
7
8
X5
JP5
7
up/downslope
extern
~
~
JP4
JP3
JP2
Projektbez.
Auftragsnr.
Zeichnungsnr.
INSQUARE W300/420DC
+SQ-A11-X3/3.3
+SQ-A11-X14/3.4
JP1
9 10 11 12 13 14 15 16
DC
ME-TF-1.2
Elektrode
ENDSTROM/
final current
ABSENKUNG/
downslope gn
gn
PUNKTZEIT/timer spot welding
ENDSTROM/final current
ABSENKUNG/downslope
I2/t2
gn
P1
ZEIT/time I1
I1/t1
gn
P2
+OP1-K1:8/3.8
STROM/current I1
20
5
+OP1-K1:12/3.8
STARTSTROM/initial curr.
STARTSTROM/
initial curr.
gn
ANSTIEG/
upslope
gn
X3
gn
gn
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
2
gn
gn
4
I2 frei
einstellbar
2
Einfache
Frontplatte/
reduced
operation panel
5
Blatt
=
+ SQ
TEST, PROG
GASTEST
2-TAKT
I2 (%)
4-TAKT
FUSSFERNR. I1
HANDFERNR. I1
BRENNER I1
MASCHINE I1
LIFT-ARC
HF
0
PUNKTEN
PULSEN SCHNELL
PULSEN LANGSAM
0
8
4
Bl.
17th3 Spare part list TIG Insquare W 300 AC/DC
electr.
02.04.2004
part no.
Description
-A0
-A1
-A2
-A3
-A4
-A5
-A6
-A7
-A8
-A9
-A10
-A11
-A12
-A13
-A14
-A15
-A16
line filter ME-NF400/2.5
pc -board ME-I-PG-1.1
pc -board ME-I-PI-1.0
pc -board ME-I-SD-1.1B
pc -board ME-I-WS-1.1
pc -board ME-I-WE-1.1
pc -board ME-I-WE-1.1
pc -board ME-I-RC-1.1
pc -board ME-I-RC-1.1
LEM- converter HTA 400 S
ignition generator SIG 8.71
pc -board ME-MTC-1.2
pc -board ME-MTC/T-1.5
pc -board ME-BT-1.5
pc -board ME-TF-1.2
pc -board ME-EMV-3.1
pc -board ME-UESW-4A
102.279
003.0.0001
003.0.0002
003.0.0003
003.0.0105
003.0.0006
003.0.0006
003.0.0004
003.0.0004
010.0.1615
020.1.1610
003.1.0042
003.0.0008
003.0.0009
003.0.0012
102.281
003.0.0007
-F1
-F2
-F3
-F4
-F6
-F7
-F8
-F9
fuse 4 A slow 6,3x32 mm
fuse 4 A slow 6,3x32 mm
fuse 10 A slow 5x20 mm
fuse 1 A slow 5x20 mm
membran switch 0,5 bar
termical switch 80°C opend – sec.- rectifier
overcurrent switch 1,4 A
termical switch 80°C opend - sec IGBT
003.0.1251
003.0.1251
003.0.1199
003.0.1212
004.0.0204
001.0.0406
003.0.0320
001.0.0406
-K1
-L1
relais 48V (option: automatic welding)
relais socket
choke (ferrit)
010.0.1961
010.0.1962
020.1.1661
-M1
-M2
-M3
-M4
-M5
fan 230 V-AC at the Inverter
fan 230 V-AC at the Inverter
fan 230 V-AC at the water cooler unit
fan 230 V-AC at the water cooler unit
waterpump 230V 50Hz 0,12 kW
001.0.1323
001.0.1323
001.0.1323
001.0.1323
004.0.0530
-Q1
Hauptschalter HLT 40/3ZM/X99/NR
001.0.0014
-R1
-R2
-R3
-R4
-R5
resistor 330 Ω-50 W
resistor 330 Ω-50 W
resistor 0,02 Ω-50W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
030.0.4583
030.0.4583
030.0.4580
030.0.4581
030.0.4581
43
electr.
Description
part no.
-R6
-R7
-R8
-R9
-R10
-R11
-R12
-R13
-R14
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
resistor 330 Ω-50 W
resistor 100 Ω-50 W
resistor 100 Ω-50 W
NTC resistor 47 kΩ (sec. IGBT)
NTC resistor 100 kΩ (transformer inside)
030.0.4581
030.0.4581
030.0.4581
030.0.4581
030.0.4583
030.0.4582
030.0.4582
010.0.1933
010.0.1934
-S1
-S3
selector (option: automatic welding)
selector 2-polig (option: welding two sides)
003.0.0900
003.0.0900
-T1
-T2
-T3
-T4
-T5
main transformer with choke
control transformer EI 120/73,7 950VA
converter
converter
converter
020.1.1661
003.0.0242
020.1.1124
020.1.1124
020.1.1124
-V1V12
-V13
-V14
-V15
-V16
-V17V20
sec. rectifier-modul
001.0.0287
prim. rectifier
thyristor modul
prim. IGBT
prim. IGBT
sec. IGBT (selected type C)
001.0.0285
001.0.0286
001.0.0173
001.0.0173
001.0.0288
-X1
-X2
-X3
-X5
-X6
-X7
-X8
TIG euro connector
bush 70/95mm² 500A
bush 70/95mm² 500A
5-pol.socket (torch switch)
10-pol. socket (option: remote control)
10-pol. plug (acessories)
strain relief (acessories)
connector 6-pol. pin (Option automatic welding)
3-pol. socket (Option: welding two sides)
025.1.1685
001.0.1102
001.0.1102
021.1.0394
021.1.0382
021.1.0383
021.1.0388
015.0.0102
101.009
-Y1
magnetic valve 42V/AC
002.0.1602
-Z1
-Z2
protection circuit
protection circuit
003.0.0330
003.0.0334
17th4 Wiring diagram INS W 300 AC/DC
44
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
T1 T2 T3
L 1 ´L 2 ´L 3 ´
+SQ
-A15
L1 L2 L3 PE
sw
Änderung
sw
15.11.99
Datum
-R1
-R2
Plotdatum: 07.10.03
a
b
c
d
+SQ
-Q1
br
L1 L2 L3
sw
sw
sw
sw
+SQ-W1
bl
sw
sw
sw
1
Konrad
Name
bl
2
1
2
L3
L2
PE
Erdungsschraube
bl
br
bl
PE
gn-ge
L1 L2 L3
ME-EMV-3.0
3
rt
4
4
1
+ U>
bl
-
Siegner
Name
gepr. 21.02.00
Datum
-A1
+
3
bl
-
-
-
-
-
-R3
ME-I-PG-1.1
Prim.DC
gn
-V14
+
+
U<
10
Konrad
gez.
X4
F3
F2
-V13
U>Umax U<Umin
0,2A
0,2A
0,2A
F1
L3
L2
L1
rt
X2
+SQ-T2:0V/3.2
+SQ-T2:400V/3.2
01.06.99
1
2
1
-
2
1
3
rt
br
gr
X1
+
Überst./ rt
2 X3
over current
2
L3´
L2´
1
+SQ
-A0
ME-NF400/2.5
2
rt
1
bl
bl
2
3
X3
16
X1
5
6
7
8
ME-I-RC-1.1
4
1
-A2
ME-I-PI-1.0
T-Prim.
-- V 1 6
+
+
-- V 1 5
T-Prim.
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
-A7
1
-T1
-T3
4
5
1
bl
-A8
rt
2
3
X1
5
6
7
8
ME-I-RC-1.1
4
Schweißstromkreis
bl
3PH-400V/50Hz/PE
rt
2
4
3
2
1
2
4
3
2
1
3
1
2
-V11
3
4
3
4
3
4
3
4
1
2
-V12
1
2
-V9
1
2
-V6
1
2
-V3
7
3
4
3
4
3
4
3
4
Auftragsnr.
Zeichnungsnr.
bl
bl
rt
INSQUARE W300 AC/DC
Projektbez.
1
2
4
3
1
-V10
2
4
2
1
-V8
-V7
1
-V5
-V4
1
-V2
ws
+INV-W3
-V1
ws
+INV-W2
6
bl
bl
rt
rt
bl
6
Blatt
Bl.
1
D+/2.1
C+/2.1
=
+ INV
bl
B+/2.1
A+/2.1
E-/2.1
+INV-R12/2.6
+INV-A4-X5:1/2.6
+INV-A3-X12/3.4
+INV-A3-X4/3.6
8
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Änderung
Datum
sw
3
2
+INV-W14
2
1
sw
1
rt
gn
ge
+INV-W15
-A9
Plotdatum: 07.10.03
a
b
c
d
D+/1.8
B+/1.8
C+/1.8
A+/1.8
E-/1.8
+INV-A3-X10:1/3.4
+INV-A3-X10:2/3.4
+INV-A3-X10:3/3.4
+INV-A3-X10:4/3.4
4
X1
+
~
X5
1
2
Siegner
gepr. 21.02.00
Name
1
2
Konrad
Datum
3
X2
2
2
-R8
1
2
1
1
2
-R6
-R10
sw
+INV-W16
-R4
sw
DB
-Z2
+INV-W12
X3 1
ME-I-WE-1.1
-V18
-
2
1
X4
2
1
HF-Drossel L1 im
Inverter Draufsicht
12.07.99
gez.
-V17
-A5
Name
1
26
1 X6
2
+INV-W17
4
3
D0
Ferritkern
sw
3
Wicklung HF-Drossel
X1
-V19
-A6
DB D0
T0 T70
~
2
2
X5
ws
2
2
1
1
-R9
2
1
2
1
-R7
-T4
bl
sw
rt
Schweißstromkreis
ws
+INV-W5
-R11
3
3
X2
2
1
2
X3 1
X4
1
1
sw
-R5
+INV-W13
ME-I-WE-1.1
-V20
-
5
+SQ-W10
42V~
+INV-W4
+
-A10
Zündgerät SIG 8.71/
ignition generator
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
1
26
1 X6
2
-L1
4
rt
2
bl
bl
sw
1
6
bl
1
2
3
4
5
6
7
8
X4
X5
1
gn
X2
3
X6
1
2
1
Auftragsnr.
28
27
26
1
6
Blatt
2
Bl.
=
+ INV
+SQ-T2:0/230V/3.2
+SQ-T2:230V/3.2
+INV-A3-X1/3.5
+SQ-A11-X2/4.4
+INV-T1/1.4
+INV-T1/1.4
+SQ-A16-X4:1/3.2
+INV-A3-X7:4/3.5
+SQ-A16-X4:3/3.2
+INV-A3-X7:1/3.5
+
+SQ Werkstück
-X3 work piece
34
X3
Zeichnungsnr.
INSQUARE W300 AC/DC
4
4
ME-I-WS-1.0
- Pol
ISD
1
ws
+INV-W7
X1
+ Pol
rt
34
ws
-
Elektrode
stick elektrode
-
+SQ-A16-X2:1/3.2
+SQ-A16-X2:2/3.2
+INV-A3-X8:1/3.6
+INV-A3-X8:2/3.6
+INV-A3-X8:6/3.6
+SQ-T2:w3-0V/3.2
8
+SQ Brenner
-X1 torch
+SQ
-X2
rt
sw
bl
rt
bl
+INV-W6
-A4
sw
+SQ-W11
-Z1
7
MTC
Projektbez.
1
26
1
2
3
4
5
6
7
8
-R12
-T5
23
25
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Änderung
PE
w12-0V
w12-42V 1A
-F4
w2-0V
X3
4
3
U<48V
Name
X2
X5
X4
2
1
4
3
2
1
-F3
16
w10-9V
Siegner
Name
rt
bl
gepr. 21.02.00
gn
gn
w11-0V
+INV-A10:42V~/2.4
18
NTC-IGBT
bl
+INV
-R13
+INV
-F9
+INV
-F7
+INV-T5/2.6
+INV-T5/2.6
+SQ-A14-X3:2/5.3
+SQ-A14-X3:1/5.3
+INV-A5:~/2.1
sw
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
X5
ge
rt
ge
rt
X2
X10
X6
1
gn
16
ge
LT
UeT
LI
UeI
+5V
gn
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
+INV-A5:~/2.1
-15V
gn
Reg.
Spr.
PU500
I>0
intern
ext
Res
intern
rt
4
+
bl
3
1
2
Untersp./under voltage
Übersp./over voltage
Übertemp./over temp.
1
-
Wasserp./
pump
Lüfter/
fan
RES
I>0
HF
Gas
rt
rt
rt
rt
rt
gn
gn
rt
rt
rt
ge
I>0
Res.
Gas
MAG TIG
I>0
Start
POL
T>50C°
rt
rt
rt
rt
Erdungsschraube
X9
X14
6
5
4
3
2
1
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
10
1
24
6
X8
X4
34
Steuerstromkreis
4
X7
U ist
Istat.
Idyn.
X1
Störung/failure
1
25
WD.fehlt/no water pressure
ME-I-SD-1.1
+15V
gn
Idyn
rt
+INV
-A3
+15VP PWM-ON Istat
gn
X12
+INV-A5-X5:2/2.3
+INV
-R14
NTC-Trafo
rt
bl
rt
1
2
3
4
1
2
3
4
5
6
7
8
+SQ-A11-X1:1/4.2
+SQ-A11-X1:2/4.2
+SQ-A11-X1:3/4.2
+SQ-A11-X1:4/4.2
25
+INV-A5-X5:2/2.3
19
18
15
w9-0V
w11-9V
14
w9-18V
17
13
w8-0V
w10-0V
12
w8-18V
w7-0V
w7-18V
w6-0V
19
23
w5-0V
Konrad
Datum
rt
gn
ge
bl
22
w5-9V
w6-9V
21
20
w3-37V
w3-42V
w4-18V
w4-0V
10A w3-0V
01.06.99
gez.
1
2
2
1
8
32
8
31
bl
7
7
3
1
6
5
4
3
2
1
rt
+INV-A9-X1:4/2.2
+INV-A9-X1:4/2.2
+INV-A9-X1:4/2.2
1
gn
-F2
+INV-A9-X1:4/2.2
2
2
4A
sw1/sw2
w2-9V
0V
0/230V
w1
230V
0/230V
4A
-F1
400V
Erdungsschraube
bn
1
Datum
I>0
rt
-A16
Plotdatum: 07.10.03
a
b
c
d
28
gr
ME-UESW-4
+SQ-A0:L3´/1.2
+INV-A3-X9:1/3.6
+INV-A4-X6:4/2.7
27
27
28
+SQ-A0:L2´/1.2
1A
5A
1A
1A
2A
1A
1A
1A
1A
1A
+INV-A4-X6:1/2.7
+INV-A3-X9:2/3.6
IGBT
Gleichrichter/
rectifier
sw
5
Lüfter/fan
4
Wasserp./pump
3
27
5
27
27
28
24
24
PE
5
1
2
4
M
Auftragsnr.
24
PE
Zeichnungsnr.
M
Lüfter/ PE
fan
+INV
-M1
P
PE
-M3
M
+OP1-X7:2/4.1
+OP1-X7:1/4.1
-M4
M
+INV-T4/2.6
+INV-T4/2.6
+INV-A1-X2/1.2
+INV-A4-X2/2.7
+INV-A2-X3/1.5
8
Blatt
=
+ SQ
M
6
Bl.
3
PE
+INV
-X5
+INV-A10:42V~/2.4
-F6
INSQUARE W300 AC/DC
PE
-M5
+SQ-T2:230V/3.2
3
bl
rt
23
+INV
-M2
+SQ-T2:0V/3.2
24
3
-X4
5
1
2
4
3
3
-Y1
26
Projektbez.
-F8
6
30
27
25
4
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
7
bl
2
br
-T2
schw
1
Pumpe/
pump
Lüfter/
fan
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Not-Aus/emergency stop
Not-Aus/emergency stop
Schweissen ein/welding on
Schweissen ein/welding on
Lichtbogen I>0/arc ok
Lichtbogen I>0/arc ok
4 Windungen/
Datum
2
3
5
7
4 turns
6
Plotdatum: 07.10.03
a
b
c
d
4
Änderung
1
K1
Name
4
3
8
2
7
1
6
5
12
11
10
9
25
2
6
5
4
3
2
5
4
3
2
1
5
4
3
2
1
X9
X4
B
A
GND
Siegner
gepr. 21.02.00
X3
Energy
1
2
ge
3
A1
A2
X7
4
3
sw
5
6
5
24
+OP1
-K1
1
26
X14
ws
X12
3
2
X10
1
-A12
1
4 3 2 1
4 3 2 1
4
X2
34
+SQ-A14-X1/5.5
+SQ-A14-X2/5.6
JP2
1
6
5
4
3
2
1
6
5
4
3
2
1
TOUT
TIN
AGND
K
ein
+OP2
-S2
3
2
1
I
X1
E
-X6
FT
E
X3
F
G
D
D
C
C
S
B
B
E
A
A
A
-A13
1
2
3
ge
4
X5
2
1
3
2
BT. Poti
7
1
1
31
.3
+OP1
-K1
31
Auftragsnr.
9
Zeichnungsnr.
INSQUARE W300 AC/DC
Projektbez.
2
2
torch
switch
2
BT2
3
3
X2
4
4
oder/
or
torch
switch
1
BT1
1
1
8
S
5
4
gn
.3
+OP1
-K1
12
8
6
Blatt
=
+ SQ
gn
Brenner mit Doppeltaster
oder mit Brennerpoti/
torch with 2 button
or with torch poti
-X5
5
ME-BT-1.5
Option:
Automatenanschluß/
machine welding connection
+SQ-A14-X3:1/5.3
+INV-A3-X6:7/3.4
Doppelseitiges
Schweissen aus
+SQ-A16-X4:7/3.2
+SQ-A16-X5:1/3.2
Fußfernregler/
foot remote control
H
Poti Fern/remote control
Fußt/switch foot pedal
TIG/BT2/torch switch 2
REF50
X4
TEST
BT/torch switch
+INV-A4-X1/2.7
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
6
Option: Doppelseitiges Schweissen/
option: welding two sides
7
9
10
7
5
Steuerstromkreis
1
X15
ME-MTC/T-1.5
X1
Anpassung
Spannungsanzeige/
adjust voltage
display
X13
X11
1
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
ws
1
X5
10
sw
ge
+SQ-T2:w3-42V/3.2
+SQ-W9
1 9
X8
4
+SQ-T2:w3-0V/3.2
+SQ-W8
ME-MTC-1.2
1
+INV-A3-X8:8/3.6
+INV-A3-X8:7/3.6
-A11
Korrektur/trim
Name
20
1
2
3
4
X6
16
3
3
3
Taster Draht/button wire feed
+5V
X1
1
Konrad
Datum
7
6
6
1
8
7
1
2
3
4
7
1
2
3
4
01.06.99
23
22
21
20
3
Hand/Automatik
1
26
10
9
Ferritring /
feritt ring
gez.
.8
.7
+SQ-T2:w5-0V/3.2
+SQ-T2:w5-9V/3.2
+SQ-T2:w4-0V/3.2
+SQ-T2:w4-18V/3.2
2
+OP1
-S1
3 Windungen/
3 turns
Option:
Automatenanschluß/
machine welding connection
6
5
4
3
2
1
+OP1
-X7
1
1
GND
1
4
Bl.
E
A
Brennerpoti/torch poti
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Änderung
HOLD
gn
Datum
Plotdatum: 07.10.03
a
b
c
d
<48V
RMS
S TEST
U
gn
Störung/
failure
rt
Übertemperatur/
overtemp.
ge
NETZ/
main
gn
1
Name
Siegner
gepr. 21.02.00
Name
Konrad
Datum
Hz
S
A
kHz
Hz
S
01.06.99
gez.
PROGRAMM-NR.
-A14
V
A
3
1
1
ANSTIEG/upslope
STROM/current I1
20
X1
TIG-ELEKTRODE O mm
AC FREQUENZ/frequency
AC BALANCE + (%)
ZEIT t2/time t2
STROM I2/current I2
GAS:VORSTRÖMEN/preflow
ZÜNDIMPULS/ingniton pulse
STARTSTROM/initial curr.
STARTSTROM/
initial curr.
gn
ANSTIEG/
upslope
gn
X3
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
2
gn
gn
4
1
16
gn
gn
DISPLAY: SPANNUNG/voltage
GAS:NACHSTRÖMEN/postflow
X2
1
Frontplatine
26
STROMNACHREGELUNG/arc force
HOTSTART-STROM/current
HOTSTART-ZEIT/timer
JP8
Plasma
JP7
ROB
+
+
+
-
TIG
JP6
300A
JP5
7
~
~
JP4
up/downslope
extern
JP3
JP2
DC
Auftragsnr.
JP1
TEST, PROG
GASTEST
2-TAKT
I2 (%)
4-TAKT
FUSSFERNR. I1
HANDFERNR. I1
BRENNER I1
MASCHINE I1
LIFT-ARC
HF
0
PUNKTEN
PULSEN SCHNELL
PULSEN LANGSAM
0
8
+SQ-A11-X3/4.3
6
Blatt
=
+ SQ
+SQ-A11-X14/4.3
Zeichnungsnr.
INSQUARE W300 AC/DC
Projektbez.
ME-TF-1.2
Elektrode
ENDSTROM/
final current
ABSENKUNG/
downslope gn
gn
6
JP6 bei Insquare W420 AC/DC
nicht gesteckt
PUNKTZEIT/timer spot welding
ENDSTROM/final current
ABSENKUNG/downslope
I2/t2
gn
P1
+SQ-A16-X5:2/3.2
+SQ-A16-X5:1/3.2
ZEIT/time I1
I1/t1
gn
P2
5
I2 frei
einstellbar
2
Einfache
Frontplatte/
reduced
operation panel
5
Bl.
17th5 Spare part list TIG Insquare W 420 AC/DC
electr.
02.04.2004
part no.
Description
-A0
-A1
-A2
-A3
-A4
-A5
-A6
-A7
-A8
-A9
-A10
-A11
-A12
-A13
-A14
-A15
-A16
line filter ME-NF400/2.5
pc -board ME-I-PG-1.1
pc -board ME-I-PI-1.0
pc -board ME-I-SD-1.1B
pc -board ME-I-WS-1.1
pc -board ME-I-WE-1.1
pc -board ME-I-WE-1.1
pc -board ME-I-RC-1.1
pc -board ME-I-RC-1.1
LEM- converter HTA 400 S
ignition generator SIG 8.71
pc -board ME-MTC-1.2
pc -board ME-MTC/T-1.5
pc -board ME-BT-1.5
pc -board ME-TF-1.2
pc -board ME-EMV-3.1
pc -board ME-UESW-4A
102.279
003.0.0001
003.0.0002
003.0.0003
003.0.0105
003.0.0006
003.0.0006
003.0.0004
003.0.0004
010.0.1615
020.1.1610
003.1.0042
003.0.0008
003.0.0009
003.0.0012
102.281
003.0.0007
-F1
-F2
-F3
-F4
-F6
-F7
-F8
-F9
fuse 4 A slow 6,3x32 mm
fuse 4 A slow 6,3x32 mm
fuse 10 A slow 5x20 mm
fuse 1 A slow 5x20 mm
membran switch 0,5 bar
termical switch 80°C opend – sec.- rectifier
overcurrent switch 1,4 A
termical switch 80°C opend - sec IGBT
003.0.1251
003.0.1251
003.0.1199
003.0.1212
004.0.0204
001.0.0406
003.0.0320
001.0.0406
-K1
-L1
relais 48V (option: automatic welding)
relais socket
choke (ferrit)
010.0.1961
010.0.1962
001.0.1992
-M1
-M2
-M3
-M4
-M5
fan 230 V-AC at the Inverter
fan 230 V-AC at the Inverter
fan 230 V-AC at the water cooler unit
fan 230 V-AC at the water cooler unit
waterpump 230V 50Hz 0,12 kW
001.0.1323
001.0.1323
001.0.1323
001.0.1323
004.0.0530
-Q1
Hauptschalter HLT 40/3ZM/X99/NR
001.0.0014
-R1
-R2
-R3
-R4
-R5
resistor 330 Ω-50 W
resistor 330 Ω-50 W
resistor 0,02 Ω-50W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
030.0.4583
030.0.4583
030.0.4580
030.0.4581
030.0.4581
50
electr.
Description
part no.
-R6
-R7
-R8
-R9
-R10
-R11
-R12
-R13
-R14
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
resistor 330 Ω-50 W
resistor 100 Ω-50 W
resistor 100 Ω-50 W
NTC resistor 47 kΩ (sec. IGBT)
NTC resistor 100 kΩ (transformer inside)
030.0.4581
030.0.4581
030.0.4581
030.0.4581
030.0.4583
030.0.4582
030.0.4582
010.0.1933
010.0.1934
-S1
-S3
selector (option: automatic welding)
selector 2-polig (option: welding two sides)
003.0.0900
003.0.0900
-T1
-T2
-T3
-T4
-T5
main transformer with choke
control transformer EI 120/73,7 950VA
converter
converter
converter
020.1.1661
003.0.0242
020.11124
020.1.1124
020.1.1124
-V1V12
-V13
-V14
-V15
-V16
-V17V20
sec. rectifier-modul
001.0.0287
prim. rectifier
thyristor modul
prim. IGBT
prim. IGBT
sec. IGBT (selected type A or B)
001.0.0285
001.0.0286
001.0.0173
001.0.0173
00100288
-X1
-X2
-X3
-X5
-X6
-X7
-X8
TIG euro connector
bush 70/95mm² 500A
bush 70/95mm² 500A
5-pol.socket (torch switch)
10-pol. socket (option: remote control)
10-pol. plug (acessories)
strain relief (acessories)
connector 6-pol. pin (Option automatic welding)
3-pol. socket (Option: welding two sides)
025.1.1685
001.0.1102
001.0.1102
021.1.0394
021.1.0382
021.1.0383
021.1.0388
015.0.0102
101.009
-Y1
-Z1
-Z2
magnetic valve 42V/AC
protection circuit
protection circuit
002.0.1602
003.0.0330
003.0.0334
17th6 Wiring diagram INS W 420 AC/DC
51
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
sw
Änderung
sw
L 1 ´L 2 ´L 3 ´
+SQ
-A15
L1 L2 L3 PE
T1 T2 T3
15.11.99
Datum
-R1
-R2
sw
Plotdatum: 07.10.03
a
b
c
d
+SQ
-Q1
L1 L2 L3
L1 L2 L3
1
Konrad
Name
bl
2
1
2
L3
L2
PE
Erdungsschraube
bl
br
bl
PE
ME-EMV-3.0
3
rt
4
4
1
+ U>
bl
-
Siegner
Name
gepr. 21.02.00
Datum
-A1
+
3
bl
-
-
-
-
-
-R3
ME-I-PG-1.1
Prim.DC
gn
-V14
+
+
U<
Konrad
gez.
X4
F3
F2
-V13
U>Umax U<Umin
0,2A
0,2A
0,2A
F1
L3
L2
L1
rt
X2
10
+SQ-T2:0V/3.2
+SQ-T2:400V/3.2
01.06.99
1
2
1
-
2
1
3
rt
br
gr
X1
+
Überst./ rt
2 X3
over current
2
L3´
L2´
1
+SQ
-A0
ME-NF400/2.5
2
rt
1
bl
bl
2
3
X3
16
X1
5
6
7
8
ME-I-RC-1.1
4
1
-A2
ME-I-PI-1.0
T-Prim.
-- V 1 6
+
+
-- V 1 5
T-Prim.
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
-A7
1
-T1
-T3
4
5
1
bl
-A8
rt
2
3
X1
5
6
7
8
ME-I-RC-1.1
4
Schweißstromkreis
bl
3PH-400V/50Hz/PE
rt
6
2
4
3
2
1
2
4
3
2
1
3
1
2
-V11
3
4
3
4
3
4
3
4
1
2
-V12
1
2
-V9
1
2
-V6
1
2
-V3
3
4
3
4
3
4
3
4
Auftragsnr.
Zeichnungsnr.
bl
bl
rt
INSQUARE W420 AC/DC
Projektbez.
1
2
4
3
1
-V10
2
4
2
1
-V8
-V7
1
-V5
-V4
1
-V2
-V1
7
bl
bl
rt
rt
bl
6
Blatt
Bl.
1
D+/2.1
C+/2.1
=
+ INV
bl
B+/2.1
A+/2.1
E-/2.1
+INV-R12/2.6
+INV-A4-X5:1/2.6
+INV-A3-X12/3.4
+INV-A3-X4/3.6
8
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Änderung
Datum
sw
3
2
+INV-W14
2
1
sw
1
rt
gn
ge
+INV-W15
-A9
Plotdatum: 07.10.03
a
b
c
d
D+/1.8
B+/1.8
C+/1.8
A+/1.8
E-/1.8
+INV-A3-X10:1/3.4
+INV-A3-X10:2/3.4
+INV-A3-X10:3/3.4
+INV-A3-X10:4/3.4
4
X1
+
~
X5
1
2
Siegner
gepr. 21.02.00
Name
1
2
Konrad
Datum
3
X2
2
2
-R8
1
2
1
1
2
-R6
-R10
sw
+INV-W16
-R4
sw
DB
-Z2
+INV-W12
X3 1
ME-I-WE-1.1
-V18
-
2
1
X4
2
1
HF-Drossel L1 im
Inverter Draufsicht
12.07.99
gez.
-V17
-A5
Name
1
26
1 X6
2
+INV-W17
4
3
D0
Ferritkern
sw
3
Wicklung HF-Drossel
X1
-V19
-A6
DB D0
T0 T70
~
2
2
X5
ws
2
2
1
1
-R9
2
1
2
1
-R7
-T4
bl
sw
rt
Schweißstromkreis
ws
+INV-W5
-R11
3
3
X2
2
1
2
X3 1
X4
1
1
sw
-R5
+INV-W13
ME-I-WE-1.1
-V20
-
5
+SQ-W10
42V~
+INV-W4
+
-A10
Zündgerät SIG 8.71/
ignition generator
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
1
26
1 X6
2
-L1
4
rt
2
bl
bl
sw
1
6
bl
1
2
3
4
5
6
7
8
X4
X5
1
gn
X2
3
X6
1
2
1
Auftragsnr.
28
27
26
1
6
Blatt
2
Bl.
=
+ INV
+SQ-T2:0/230V/3.2
+SQ-T2:230V/3.2
+INV-A3-X1/3.5
+SQ-A11-X2/4.4
+INV-T1/1.4
+INV-T1/1.4
+SQ-A16-X4:1/3.2
+INV-A3-X7:4/3.5
+SQ-A16-X4:3/3.2
+INV-A3-X7:1/3.5
+
+SQ Werkstück
-X3 work piece
34
X3
Zeichnungsnr.
INSQUARE W420 AC/DC
4
4
ME-I-WS-1.0
- Pol
ISD
1
ws
+INV-W7
X1
+ Pol
rt
34
ws
-
Elektrode
stick elektrode
-
+SQ-A16-X2:1/3.2
+SQ-A16-X2:2/3.2
+INV-A3-X8:1/3.6
+INV-A3-X8:2/3.6
+INV-A3-X8:6/3.6
+SQ-T2:w3-0V/3.2
8
+SQ Brenner
-X1 torch
+SQ
-X2
rt
sw
bl
rt
bl
+INV-W6
-A4
sw
+SQ-W11
-Z1
7
MTC
Projektbez.
1
26
1
2
3
4
5
6
7
8
-R12
-T5
23
25
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Änderung
PE
w12-0V
w12-42V 1A
-F4
w2-0V
X3
4
3
U<48V
Name
X2
X5
X4
2
1
4
3
2
1
-F3
16
w10-9V
Siegner
Name
rt
bl
gepr. 21.02.00
gn
gn
w11-0V
18
NTC-IGBT
bl
+INV
-R13
+INV
-F9
+INV
-F7
+INV-T5/2.6
+INV-T5/2.6
+SQ-A14-X3:2/5.3
+SQ-A14-X3:1/5.3
+INV-A5:~/2.1
sw
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
X5
ge
rt
ge
rt
X2
X10
X6
1
gn
16
ge
LT
UeT
LI
UeI
+5V
gn
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
+INV-A5:~/2.1
-15V
gn
Reg.
Spr.
PU500
I>0
intern
ext
Res
intern
rt
4
+
bl
3
1
2
Untersp./under voltage
Übersp./over voltage
Übertemp./over temp.
1
-
Wasserp./
pump
Lüfter/
fan
RES
I>0
HF
Gas
rt
rt
rt
rt
rt
gn
gn
rt
rt
rt
ge
I>0
Res.
Gas
MAG TIG
I>0
Start
POL
T>50C°
rt
rt
rt
rt
Erdungsschraube
X9
X14
6
5
4
3
2
1
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
10
1
24
6
X8
X4
34
Steuerstromkreis
4
X7
U ist
Istat.
Idyn.
X1
Störung/failure
1
WD.fehlt/no water pressure
ME-I-SD-1.1
+15V
gn
Idyn
rt
+INV
-A3
+15VP PWM-ON Istat
gn
X12
+INV-A5-X5:2/2.3
+INV
-R14
NTC-Trafo
rt
bl
rt
1
2
3
4
1
2
3
4
5
6
7
8
+SQ-A11-X1:1/4.2
+SQ-A11-X1:2/4.2
+SQ-A11-X1:3/4.2
+SQ-A11-X1:4/4.2
+INV-A10:42V~/2.4
+INV-A5-X5:2/2.3
19
18
15
w9-0V
w11-9V
14
w9-18V
17
13
w8-0V
w10-0V
12
w8-18V
w7-0V
w7-18V
w6-0V
19
23
w5-0V
Konrad
Datum
rt
gn
ge
bl
22
w5-9V
w6-9V
21
20
w3-37V
w3-42V
w4-18V
w4-0V
10A w3-0V
01.06.99
gez.
1
2
2
1
8
32
8
31
bl
7
7
3
1
6
5
4
3
2
1
rt
+INV-A9-X1:4/2.2
+INV-A9-X1:4/2.2
+INV-A9-X1:4/2.2
1
gn
-F2
+INV-A9-X1:4/2.2
2
2
4A
sw1/sw2
w2-9V
0V
0/230V
w1
230V
0/230V
4A
-F1
400V
Erdungsschraube
bn
1
Datum
I>0
rt
-A16
Plotdatum: 07.10.03
a
b
c
d
28
gr
ME-UESW-4
+SQ-A0:L3´/1.2
+INV-A3-X9:1/3.6
+INV-A4-X6:4/2.7
27
27
28
+SQ-A0:L2´/1.2
1A
5A
1A
1A
2A
1A
1A
1A
1A
1A
+INV-A4-X6:1/2.7
+INV-A3-X9:2/3.6
IGBT
Gleichrichter/
rectifier
sw
5
Lüfter/fan
4
Wasserp./pump
3
27
2
27
27
28
24
PE
5
4
3
2
M
Auftragsnr.
24
PE
Zeichnungsnr.
M
Lüfter/ PE
fan
+INV
-M1
P
PE
-M3
M
+OP1-X7:2/4.1
+OP1-X7:1/4.1
-M4
M
+INV-T4/2.6
+INV-T4/2.6
+INV-A1-X2/1.2
+INV-A4-X2/2.7
+INV-A2-X3/1.5
8
Blatt
=
+ SQ
M
6
Bl.
3
PE
+INV
-X5
+INV-A10:42V~/2.4
-F6
INSQUARE W420 AC/DC
PE
-M5
25
24
+SQ-T2:230V/3.2
1
bl
rt
23
+INV
-M2
+SQ-T2:0V/3.2
24
3
-X4
5
4
3
2
1
3
-Y1
26
Projektbez.
-F8
6
30
27
25
4
3
5
1
12
11
10
9
8
7
6
5
4
3
2
1
7
bl
2
br
-T2
schw
1
Pumpe/
pump
Lüfter/
fan
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Not-Aus/emergency stop
Not-Aus/emergency stop
Schweissen ein/welding on
Schweissen ein/welding on
Lichtbogen I>0/arc ok
Lichtbogen I>0/arc ok
4 Windungen/
Datum
2
3
5
7
4 turns
6
Plotdatum: 07.10.03
a
b
c
d
4
Änderung
1
K1
Name
4
3
8
2
7
1
6
5
12
11
10
9
25
2
6
5
4
3
2
5
4
3
2
1
5
4
3
2
1
X9
X4
B
A
GND
Siegner
gepr. 21.02.00
X3
Energy
1
2
ge
3
A1
A2
X7
4
3
sw
5
6
5
24
+OP1
-K1
1
26
X14
ws
X12
3
2
X10
1
-A12
1
4 3 2 1
4 3 2 1
4
X2
34
+SQ-A14-X1/5.5
+SQ-A14-X2/5.6
JP2
1
6
5
4
3
2
1
6
5
4
3
2
1
TOUT
TIN
AGND
K
ein
+OP2
-S2
3
2
1
I
X1
E
-X6
FT
E
X3
F
G
D
D
C
C
S
B
B
E
A
A
A
-A13
1
2
3
ge
4
X5
2
1
3
2
BT. Poti
7
1
1
31
.3
+OP1
-K1
31
Auftragsnr.
9
Zeichnungsnr.
INSQUARE W420 AC/DC
Projektbez.
2
2
torch
switch
2
BT2
3
3
X2
4
4
oder/
or
torch
switch
1
BT1
1
1
8
S
5
4
gn
.3
+OP1
-K1
12
8
6
Blatt
=
+ SQ
gn
Brenner mit Doppeltaster
oder mit Brennerpoti/
torch with 2 button
or with torch poti
-X5
5
ME-BT-1.5
Option:
Automatenanschluß/
machine welding connection
+SQ-A14-X3:1/5.3
+INV-A3-X6:7/3.4
Doppelseitiges
Schweissen aus
+SQ-A16-X4:7/3.2
+SQ-A16-X5:1/3.2
Fußfernregler/
foot remote control
H
Poti Fern/remote control
Fußt/switch foot pedal
TIG/BT2/torch switch 2
REF50
X4
TEST
BT/torch switch
+INV-A4-X1/2.7
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
6
Option: Doppelseitiges Schweissen/
option: welding two sides
7
9
10
7
5
Steuerstromkreis
1
X15
ME-MTC/T-1.5
X1
Anpassung
Spannungsanzeige/
adjust voltage
display
X13
X11
1
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
ws
1
X5
10
sw
ge
+SQ-T2:w3-42V/3.2
+SQ-W9
1 9
X8
4
+SQ-T2:w3-0V/3.2
+SQ-W8
ME-MTC-1.2
1
+INV-A3-X8:8/3.6
+INV-A3-X8:7/3.6
-A11
Korrektur/trim
Name
20
1
2
3
4
X6
16
3
3
3
Taster Draht/button wire feed
+5V
X1
1
Konrad
Datum
7
6
6
1
8
7
1
2
3
4
7
1
2
3
4
01.06.99
23
22
21
20
3
Hand/Automatik
1
26
10
9
Ferritring /
feritt ring
gez.
.8
.7
+SQ-T2:w5-0V/3.2
+SQ-T2:w5-9V/3.2
+SQ-T2:w4-0V/3.2
+SQ-T2:w4-18V/3.2
2
+OP1
-S1
3 Windungen/
3 turns
Option:
Automatenanschluß/
machine welding connection
6
5
4
3
2
1
+OP1
-X7
1
1
GND
1
4
Bl.
E
A
Brennerpoti/torch poti
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Änderung
HOLD
gn
Datum
Plotdatum: 07.10.03
a
b
c
d
<48V
RMS
S TEST
U
gn
Störung/
failure
rt
Übertemperatur/
overtemp.
ge
NETZ/
main
gn
1
Name
Siegner
gepr. 21.02.00
Name
Konrad
Datum
Hz
S
A
kHz
Hz
S
01.06.99
gez.
PROGRAMM-NR.
-A14
V
A
3
1
1
ANSTIEG/upslope
STROM/current I1
20
X1
TIG-ELEKTRODE O mm
AC FREQUENZ/frequency
AC BALANCE + (%)
ZEIT t2/time t2
STROM I2/current I2
GAS:VORSTRÖMEN/preflow
ZÜNDIMPULS/ingniton pulse
STARTSTROM/initial curr.
STARTSTROM/
initial curr.
gn
ANSTIEG/
upslope
gn
X3
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
2
gn
gn
4
1
16
gn
gn
DISPLAY: SPANNUNG/voltage
GAS:NACHSTRÖMEN/postflow
X2
1
Frontplatine
26
STROMNACHREGELUNG/arc force
HOTSTART-STROM/current
HOTSTART-ZEIT/timer
6
JP8
Plasma
JP7
ROB
+
+
+
-
TIG
JP6
300A
JP5
7
~
~
JP4
up/downslope
extern
JP3
JP2
DC
Auftragsnr.
JP1
TEST, PROG
GASTEST
2-TAKT
I2 (%)
4-TAKT
FUSSFERNR. I1
HANDFERNR. I1
BRENNER I1
MASCHINE I1
LIFT-ARC
HF
0
PUNKTEN
PULSEN SCHNELL
PULSEN LANGSAM
0
8
+SQ-A11-X3/4.3
6
Blatt
=
+ SQ
+SQ-A11-X14/4.3
Zeichnungsnr.
INSQUARE W420 AC/DC
Projektbez.
ME-TF-1.2
Elektrode
ENDSTROM/
final current
ABSENKUNG/
downslope gn
gn
PUNKTZEIT/timer spot welding
ENDSTROM/final current
ABSENKUNG/downslope
I2/t2
gn
P1
+SQ-A16-X5:2/3.2
+SQ-A16-X5:1/3.2
ZEIT/time I1
I1/t1
gn
P2
5
I2 frei
einstellbar
2
Einfache
Frontplatte/
reduced
operation panel
5
Bl.
17th7 Spare part list TIG Insquare W 600 AC/DC
electr.
02.04.2004
part no.
Description
-A1m
-A1s
-A2m
-A2s
-A3m
-A3s
-A4
-A5m
-A5s
-A6m
-A6s
-A7m
-A7s
-A8m
-A8s
-A9m
-A9s
-A10
-A11
-A12
-A13
-A14
-A15m
-A15s
-A16
-A18
-A21
-A22
pc-board ME-I-PG-1.1
pc -board ME-I-PG-1.1
pc -board ME-I-PI-1.0
pc -board ME-I-PI-1.0
pc -board ME-I-SD-1.1B
pc -board ME-I-SD-1.1B
pc -board ME-I-WS6-1.0
pc -board ME-I-WE-1.1
pc -board ME-I-WE-1.1
pc -board ME-I-WE-1.1
pc -board ME-I-WE-1.1
pc -board ME-I-RC-1.1
pc -board ME-I-RC-1.1
pc -board ME-I-RC-1.1
pc -board ME-I-RC-1.1
LEM- converter HTA 400 S
LEM- converter HTA 400 S
ignition generator SIG 8.71
pc -board ME-MTC-1.2
pc -board ME-MTC/T-1.6
pc -board ME-BT-1.5
pc -board ME-TF-1.2
pc -board ME-EMV-3.1
pc -board ME-EMV-3.1
pc -board ME-UESW-4A
insulating amplifier (option: control voltage)
pc -board ME-I-SDVT-1.1
line filter ME-NF400/2.5
003.0.0001
003.0.0001
003.0.0002
003.0.0002
003.0.0003
003.0.0003
003.0.0104
003.0.0006
003.0.0006
003.0.0006
003.0.0006
003.0.0004
003.0.0004
003.0.0004
003.0.0004
010.0.1615
010.0.1615
020.1.1610
003.1.0042
104.055
003.0.0009
003.0.0012
102.281
102.281
003.0.0007
101.065
003.0.0103
102.279
-F1m
-F1s
-F2m
-F2s
-F3m
-F3s
-F4m
-F4s
-F7m
-F7s
-F8
-F9
-F10m
-F10s
-F33
fuse 4 A slow 6,3x32 mm
fuse 4 A slow 6,3x32 mm
fuse 4 A slow 6,3x32 mm
fuse 4 A slow 6,3x32 mm
fuse 10 A slow 5x20 mm
fuse 10 A slow 5x20 mm
fuse 1 A slow 5x20 mm
fuse 1 A slow 5x20 mm
termical switch 80°C opend – sec.- rectifier
termical switch 80°C opend – sec.- rectifier
overcurrent switch 1,4 A
membran switch 0,5 bar
termical switch 80°C opend - sec IGBT
termical switch 80°C opend - sec IGBT
fuse holder
003.0.1251
003.0.1251
003.0.1251
003.0.1251
003.0.1199
003.0.1199
003.0.1212
003.0.1212
001.0.0406
001.0.0406
003.0.0320
004.0.0204
001.0.0406
001.0.0406
003.0.1191
57
electr.
-K1
Description
part no.
-L1
relais 48V (option: automatic welding)
relais socket
choke (ferrit)
010.0.1961
010.0.1962
103.023
-M1m
-M1s
-M2m
-M2s
-M3
-M4
-M5
-M6
-M7
fan 230 V-AC at the Inverter
fan 230 V-AC at the Inverter
fan 230 V-AC at the Inverter
fan 230 V-AC at the Inverter
fan 230 V-AC at the water cooler unit
fan 230 V-AC at the water cooler unit
waterpump 230V 50Hz 0,25 kW
fan 230 V-AC at the water cooler unit
fan 230 V-AC at the water cooler unit
001.0.1323
001.0.1323
001.0.1323
001.0.1323
001.0.1323
001.0.1323
102.853
001.0.1323
001.0.1323
-Q1
Hauptschalter HLT 40/3ZM/X99/NS
001.0.0014
-R1m
-R1s
-R2m
-R2s
-R3m
-R3s
-R4m
-R4s
-R5m
-R5s
-R7m
-R7s
-R8m
-R8s
-R9m
-R9s
-R10m
-R10s
-R13m
-R13s
-R14m
-R14s
resistor 330 Ω-50 W
resistor 330 Ω-50 W
resistor 330 Ω-50 W
resistor 330 Ω-50 W
resistor 0,02 Ω-50W
resistor 0,02 Ω-50W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
NTC resistor 47 kΩ
NTC resistor 47 kΩ
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
resistor 330 Ω-50 W
resistor 330 Ω-50 W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
resistor 3,3 Ω-50 W
030.0.4583
030.0.4583
030.0.4583
030.0.4583
030.0.4580
030.0.4580
030.0.4581
030.0.4581
030.0.4581
030.0.4581
010.0.1933
010.0.1933
030.0.4581
030.0.4581
030.0.4581
030.0.4581
030.0.4583
030.0.4583
030.0.4581
030.0.4581
030.0.4581
030.0.4581
-S1
-S3
selector (option: automatic welding)
selector 2-polig (option: welding two sides)
003.0.0900
003.0.0900
-T1m
-T1s
-T2m
-T2s
-T3s
main transformer with choke
main transformer with choke
control transformer EI 120/73,7 950VA
control transformer EI 120/73,7 950VA
converter
020.1.1661
020.11661
003.0.0242
003.0.0242
020.1.1124
58
electr.
Description
part no.
-T4m
-T4s
-T5
converter
converter
converter
020.1.1124
020.1.1124
020.1.1124
-V1m/
V1s to
V12m/
V12s
-V13m
-V13s
-V14m
-V14s
-V15m
-V15s
-V16m
-V16s
-V17m/
V17s to
-V20m/
V20s
sec. rectifier-modul
001.0.0287
prim. rectifier
prim. rectifier
thyristor modul
thyristor modul
prim. IGBT
prim. IGBT
prim. IGBT
prim. IGBT
sec. IGBT (selected type C)
001.0.0285
001.0.0285
001.0.0286
001.0.0287
001.0.0173
001.0.0173
001.0.0173
001.0.0173
001.0.0288
-X7
TIG euro connector
bush 70/95mm² 500A
bush 120mm² 600A
3-pol. socket (Option: welding two sides)
5-pol.socket (torch switch)
10-pol. socket (option: remote control)
10-pol. plug (acessories)
strain relief (acessories)
connector 6-pol. pin (Option automatic welding)
025.1.1685
001.0.1102
012.0.1503
101.009
021.1.0394
021.1.0382
021.1.0383
021.1.0388
015.0.0102
-Y1
magnetic valve 42V/AC
002.0.1602
-Z1
-Z2m
-Z2s
protection circuit
protection circuit
protection circuit
003.0.0330
003.0.0334
003.0.0334
-X1
-X2
-X3
-X4
-X5
-X6
17th8 Wiring diagram INS W 600 AC/DC
59
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
sw
T1 T2 T3
L1 L2 L3
sw
sw
Änderung
sw
L 1 ´L 2 ´L 3 ´
+SQ
-A15m
L1 L2 L3 PE
Datum
-R1m
-R2m
sw
Plotdatum: 07.10.03
a
b
c
d
+SQ
-Q1
sw
sw
sw
L1 L2 L3
2
3
2
2
1
3
4
rt
4
rt
bn
gr
1
+ U>
bl
F3
F2
F1
L3
L2
L1
-
gez.
Datum
08.01.01
+
-A1m
10
Konrad
Name
ME-I-PG-1.1
Prim.DC
gn
-V14m
+
+
U<
-V13m
U>Umax U<Umin
0,2A
0,2A
0,2A
X4
-
gepr.
1
1
1
rt
X2
bl
-
-
-
-
-
-R3m
+SQ-T2m:0V/5.1
X1
+
Überst./ rt
2 X3
over current
2
1
L3´
+SQ
L2´
-A22
3
+SQ-T2m:400V/5.1
+SQ-A15s:L2/3.1
+SQ-A15s:L3/3.1
+SQ-A15s:L1/3.1
ME-NF400/2.5
2
Name
bl
1
2
L3
L2
PE
sw
sw
sw
Erdungsschraube
bl
br
bl
PE
ME-EMV-3.1
rt
1
2
bl
bl
3
4
X3
16
6
7
8
ME-I-RC-1.1
X1
5
1
-A2m
ME-I-PI-1.0
T-Prim.
-V16m
+
-V15m
+
T-Prim.
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
-A7m
1
-T1m
-T3m
4
5
2
bl
-A8m
1
rt
3
4
6
7
8
ME-I-RC-1.1
X1
5
Schweißstromkreis
bl
3PH-400V/50Hz/PE
rt
6
2
4
3
2
1
2
4
3
2
1
3
1
2
-V11m
3
4
3
4
3
4
3
4
1
2
-V12m
1
2
-V9m
1
2
-V6m
1
2
-V3m
3
4
3
4
3
4
3
4
Auftragsnr.
bl
bl
rt
Zeichnungsnr.
Insquare 600 AC-DC
Projektbez.
1
2
4
3
1
-V10m
2
4
2
1
-V8m
-V7m
1
-V5m
-V4m
1
-V2m
-V1m
Flachbandkabel/flat band cable
Flachbandkabel/flat band cable
7
bl
bl
rt
rt
bl
9
Blatt
Bl.
1
D+/2.1
C+/2.1
=
+ INV
bl
B+/2.1
A+/2.1
+INV-L1/2.5
+INV-A3m-X12/5.4
+INV-A3m-X4/5.6
8
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Datum
-A9m
Plotdatum: 07.10.03
a
b
c
d
Änderung
D+/1.8
B+/1.8
C+/1.8
A+/1.8
+INV-T1m/1.4
+INV-A3m-X10:1/5.4
+INV-A3m-X10:2/5.4
+INV-A3m-X10:3/5.4
+INV-A3m-X10:4/5.4
1
2
3
X1
Name
1
26
2
-V18m
~
1
2
08.01.01
Datum
3
2
3
1
Konrad
Name
1
2
X2
2
1
2
1
-R14m
2
X5 1
2
X3 1
X4
1
2
DB
-R4m
HF-Drossel L1 im
Inverter Draufsicht
-
3
-Z2m
-R13m
-R10m
Wicklung HF-Drossel
ME-I-WE-1.1
gepr.
gez.
-V17m
+
D0
Ferritkern
-A5m
1 X6
2
4
1 2 3 4
rt
gn
ge
bl
-L1
1
X1
5
-V19m
T0 T70
~
2
3
3
1
2
X2
2
1
2
1
2
1
-R9m
2
X5 1
2
X3 1
X4
1
2
-R5m
ME-I-WE-1.1
-V20m
-
1
42V~
6
-R8m
-T4m
Schweißstromkreis
+
DB D0
-A10
Zündgerät SIG 8.71/
ignition generator
-A6m
26
1 X6
2
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
4
rt
1
bl
7
Auftragsnr.
Zeichnungsnr.
Insquare 600 AC-DC
Projektbez.
Flachbandkabel/flat band cable
Flachbandkabel/flat band cable
rt
rt
bl
bl
-T5 -X9m +
vio-sw
vio-ws
+
-
rt
bl
rt
bl
9
Blatt
2
Bl.
=
+ INV
+INV-A4-X3/4.6
+INV-A4-X5/4.8
+INV-A3m-X7:4/5.4
+SQ-A16-X4:1/6.2
+INV-A3m-X7:1/5.4
+SQ-A16-X4:3/6.2
+SQ-X3/4.8
+INV-T1s/3.4
+SQ-X1/4.8
+SQ-A16-X2:1/6.2
+SQ-A16-X2:2/6.2
+INV-A3m-X8:1/5.6
+INV-A3m-X8:2/5.6
+INV-A3m-X8:6/5.6
+INV-T2m:w3-0V
8
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
sw
Änderung
sw
L 1 ´L 2 ´L 3 ´
sw
Datum
-R1s
-R2s
Plotdatum: 07.10.03
a
b
c
d
sw
+SQ
-A15s
ME-EMV-3.1
L1 L2 L3 PE
sw
sw
3
2
2
1
3
4
rt
4
rt
1
+ U>
bl
1
1
F3
F2
F1
L3
L2
L1
-
gez.
Datum
08.01.01
+
-A1s
10
3
Name
Konrad
bl
-
-
-
-
-
-R3s
ME-I-PG-1.1
Prim.DC
gn
-V14s
+
+
U<
rt
X2
-V13s
U>Umax U<Umin
0,2A
0,2A
0,2A
X4
-
gepr.
2
1
X1
+
Überst./ rt
2 X3
over current
2
Name
bl
bl
1
2
1
Erdungsschraube
+SQ-Q1:T3/1.1
+SQ-Q1:T2/1.1
+SQ-Q1:T1/1.1
2
rt
1
2
bl
bl
3
4
6
7
8
ME-I-RC-1.1
X1
5
5
2
bl
-A8s
1
rt
3
4
6
7
8
ME-I-RC-1.1
X1
5
Schweißstromkreis
X3
16
1
-A2s
ME-I-PI-1.0
T-Prim.
+
-V16s
-
-V15s
+
T-Prim.
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
-A7s
1
-T1s
-T3s
4
rt
6
2
4
3
2
1
2
4
3
2
1
3
1
2
-V11s
3
4
3
4
3
4
3
4
1
2
-V12s
1
2
-V9s
1
2
-V6s
1
2
-V3s
3
4
3
4
3
4
3
4
Auftragsnr.
bl
bl
rt
Zeichnungsnr.
Insquare 600 AC-DC
Projektbez.
1
2
4
3
1
-V10s
2
4
2
1
-V8s
-V7s
1
-V5s
-V4s
1
-V2s
-V1s
bl
Flachbandkabel/flat band cable
Flachbandkabel/flat band cable
7
bl
bl
rt
rt
bl
9
Blatt
Bl.
3
I+/4.1
H+/4.1
=
+ INV
bl
G+/4.1
F+/4.1
+SQ-X1/4.8
+INV-L1/2.5
+INV-A3s-X12/6.4
+INV-A3s-X4/6.6
8
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
3
X1
-V18s
-
~
2
Datum
08.01.01
3
2
3
1
-R14s
2
1
2
1
-R13s
-R10s
Konrad
Name
1
X1
-V19s
-A6s
26
1 X6
2
+
-
~
1
2
3
1
-R9s
2
1
2
1
-R8s
rt
Schweißstromkreis
3
1
2
X2
2
2
X5 1
2
X3 1
X4
1
2
-R5s
bl
ME-I-WE-1.1
-V20s
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
Flachbandkabel/flat band cable
1
2
X2
2
X5 1
2
X3 1
X4
1
2
ME-I-WE-1.1
gepr.
gez.
-V17s
+
1
-R4s
-T4s
-X9s +
6
rt
bl
-A4
X1
10
4
4
Projektbez.
2
2
Auftragsnr.
+INV-A6m-X1/2.4
+SQ-A21-X2/7.3
+INV-A5m-X1/2.1
gn
rt-ge
Zeichnungsnr.
-
9
Blatt
Bl.
=
+ INV
+SQ-T2s:0/230V/6.2
+SQ-T2s:230V/6.2
4
+INV-A3s-X7:4/6.5
Flachbandkabel/flat band cable
or-ws
1
1
Insquare 600 AC-DC
3
3
X2
ME-I-WS6-1.0
+
1
Werkstück
work piece
Brenner
torch
Elektrode
+INV-A3s-X7:1/6.5
+SQ
-X3
+
+SQ
-X1
-
+SQ
-X2
-
+INV-A3s-X8:1/6.6
Flachbandkabel/flat band cable
rt
8
+INV-A3s-X8:2/6.6
Flachbandkabel/flat band cable
+SQ
-Z1
7
Flachbandkabel/flat band cable
1
Name
1
26
-A5s
1 X6
2
4
5
X3
Plotdatum: 07.10.03
Datum
2
-Z2s
4
26
Änderung
-A9s
1
1 2 3 4
rt
gn
ge
3
X4
a
b
c
d
I+/3.8
G+/3.8
H+/3.8
F+/3.8
+INV-X9m:+/2.7
+INV-L1/2.5
+INV-T1s/3.4
+INV-A3s-X10:1/6.4
+INV-A3s-X10:2/6.4
+INV-A3s-X10:3/6.4
+INV-A3s-X10:4/6.4
2
26
1
26
bl
X6
X5
1
1
1
26
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
gr
bn
bn
rt-sw
Änderung
Datum
Plotdatum: 07.10.03
a
b
c
d
+INV-A9m-X1:1/2.2
+INV-A9m-X1:2/2.2
+INV-A9m-X1:3/2.2
+INV-A9m-X1:4/2.2
+SQ-A21-X6:2/7.2
+SQ-A16-X4:8/6.2
Erdungsschraube
+SQ-T2s:0V/6.2
+SQ-A22:L3´/1.2
+SQ-A16-X3:4/6.2
+INV-A3m-X9:1/5.6
rt-sw
+SQ-A22:L2´/1.2
+SQ-A16-X3:1/6.2
or-ws
+INV-A3m-X9:2/5.6
+SQ-T2s:400V/6.2
0/230V
4A
w1
rt
gn
ge
bl
Name
gn-sw
gn-ws
PE
w12-0V
-F4m
w12-42V 1A
w2-0V
w2-9V
ws-bl
ws-sw
w5-9V
w5-0V
bn-sw
bn-gn
w9-18V
w9-0V
w10-9V
U
+INV
-R6m
gepr.
03.08.01
Datum
U
+INV
-R7m
NTC-IGBT
NTC-Trafo
ge-rt
ge-sw
+INV
-F10m
+INV
-F7m
Konrad
Name
+INV-A5m:~/2.1
8
7
6
bl
rt
bl
bl
rt
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
X5
ge
rt
ge
rt
X2
+15
-15
Iist
GND
gn
16
ge
LT
UeT
LI
UeI
+5V
gn
-15V
gn
Reg.
Spr.
PU500
I>0
intern
ext
Res
intern
+INV
-A3m
Idyn
rt
4
4
+
3
3
2
2
X7
U ist
Istat.
Idyn.
X1
Störung/failure
1
Untersp./under voltage
Übersp./over voltage
Übertemp./over temp.
5
gn
gn
rt
rt
rt
ge
I>0
Res.
Gas
3
4
5
6
7
8
9
10
11
12
3
4
5
6
7
8
9
10
11
12
X9
X14
6
5
6
5
4
3
3
4
2
2
1
3
2
1
2
2
1
1
X8
6
7
PE
-M7
bl
M
sw
PE
Lüfter/
fan
M
-M4
PE
Auftragsnr.
M
M
8
PE
-M3
M
Lüfter/ PE
fan
+INV
-M1m
-F9
M
P
+OP2-X7:2/9.2
+OP2-X7:1/9.2
9
Blatt
=
+ SQ
Bl.
5
Erdungsschraube
Erdungsschraube
+INV-A10:42V~/2.5
+INV-T4m/2.6
+INV-T4m/2.6
+INV-A1m-X2/1.2
+SQ-A21-X2/7.3
+INV-A2m-X3/1.5
+OP2-S1:2/9.5
Zeichnungsnr.
Insquare 600 AC-DC
PE
-M6
+SQ-T2m:230V/5.1
+INV
-M2m
vio-ws
vio-ge
vio-ge
+SQ-T2m:0/230V/5.1
Projektbez.
bl
rt-sw
or-ws
vio-ge
ws
br
vio-sw
vio-ge
or-sw
vio-ws
-Y1
bl
rt
Flachbandkabel/flat band cable
Flachbandkabel/flat band cable
vio-ge
Flachbandkabel/flat band cable
1
10
1
Steuerstromkreis
1
1
-
Wasserp./
pump
Lüfter/
fan
RES
I>0
HF
Gas
rt
rt
rt
rt
rt
rt
rt
rt
rt
X4
34
vio-ge
MAG TIG
I>0
Start
POL
T>50C°
WD.fehlt/no water pressure
ME-I-SD-1.1
+15V
gn
+15VP PWM-ON Istat
gn
X12
X10
X6
1
4
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
1
2
3
4
5
9
rt
10
1
2
3
4
1
2
3
4
5
6
7
8
+SQ-A11-X1:1/7.3
+SQ-A11-X1:2/7.3
+SQ-A11-X1:3/7.3
+SQ-A11-X1:4/7.3
+ vOi oP-2g -eK 1 : A 2 / 9 . 7
+INV-A10:42V~/2.5
+INV-A5m-X5:2/2.3
w11-0V
w11-9V
bn-ws
bl-ws
w8-0V
w10-0V
bl-gn
bl-rt
w8-18V
w7-0V
w7-18V
w6-0V
w6-9V
ws-bn
ws-rt
vio-ws
vio-ws
w3-37V
w3-42V
w4-18V
w4-0V
- F 3 m 10A w3-0V
gez.
s w 1 / s w 2- F 2 m
0V
4A
-F1m
0/230V
230V
400V
1A
5A
1A
1A
2A
1A
1A
1A
1A
1A
3
Gleichrichter/
rectifier
IGBT
2
Lüfter/fan
-T2m
Wasserp./pump
1
sw
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Änderung
3
4
rt
gn
ge
bl
4
Name
X2
X5
X4
2
1
4
3
2
1
8
7
6
5
4
3
2
1
4A
PE
w12-0V
gepr.
gez.
2
1
4
3
2
1
8
7
6
5
4
3
2
1
bn-sw
bn-gn
w9-0V
w10-9V
-T2s
w11-0V
w11-9V
Datum
rt
bl
Konrad
Name
gn
rt
gn-ws
gr-sw
ge-rt
ge-sw
NTC-IGBT
+INV
-R7s
+INV
-F10s
+INV
-F7s
+INV-T5/2.7
+INV-T5/2.7
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
1
2
3
4
1
2
3
4
5
6
7
8
+INV
-R6s
1
2
3
4
5
6
7
8
9
NTC-Trafo
U
bl
rt
10
1
2
3
4
1
2
3
4
5
6
7
8
4
X5
ge
rt
ge
rt
X2
+15
-15
Iist
GND
gn
16
ge
LT
UeT
LI
UeI
+5V
gn
-15V
gn
Reg.
Spr.
PU500
I>0
intern
ext
Res
intern
+INV
-A3s
Idyn
rt
5
+
3
3
rt
2
2
X7
Untersp./under voltage
Übersp./over voltage
Übertemp./over temp.
1
1
-
bl
Wasserp./
pump
Lüfter/
fan
RES
I>0
HF
Gas
rt
rt
rt
rt
rt
rt
rt
rt
gn
gn
rt
rt
rt
ge
I>0
Res.
Gas
6
1
2
3
4
5
6
7
8
9
10
11
12
3
4
5
6
7
8
9
10
11
12
6
5
rt
bl
sw
-F8
PE
-M5
M
Auftragsnr.
M
Pumpe/
pump
PE
+INV
-M2s
bl
Zeichnungsnr.
Lüfter/ PE
fan
+INV
-M1s
M
9
Blatt
=
+ SQ
Bl.
6
Erdungsschraube
+SQ-T2s:230V/6.2
+SQ-T2s:0/230V/6.2
+INV-T4s/4.5
+INV-T4s/4.5
+INV-A1s-X2/3.2
+SQ-A21-X3/7.3
vio-ws
or-ws
rt-sw
8
+INV-A2s-X3/3.5
rt
vio-ge
Insquare 600 AC-DC
Projektbez.
+INV-A5s-X5:2/4.3
+INV-A5s:~/4.1
6
5
4
3
3
4
2
2
1
3
2
bl
X9
X14
1
1
Flachbandkabel/flat band cable
Flachbandkabel/flat band cable
2
1
7
Flachbandkabel/flat band cable
1
10
X8
X4
34
rt
MAG TIG
I>0
Start
POL
T>50C°
Steuerstromkreis
4
4
U ist
Istat.
Idyn.
X1
Störung/failure
1
vio-ge
WD.fehlt/no water pressure
ME-I-SD-1.1
+15V
gn
+15VP PWM-ON Istat
gn
X12
X10
X6
1
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
+OP2-K1:6/7.1
+SQ-A21-X5:1/7.2
+INV-A3m-X6:8/5.4
+OP2-K1:5/7.1
+SQ-T2m:0/230V/5.1
03.08.01
bl
rt
bl-ws
w9-18V
bn-ws
bl-rt
w8-0V
w10-0V
bl-gn
3
w8-18V
w7-0V
w7-18V
w6-0V
w6-9V
w5-0V
w5-9V
w3-37V
w3-42V
w4-18V
w4-0V
+SQ-T2m:230V/5.1
w12-42V 1A
-F4s
w2-0V
w2-9V
s w 1 / s w 2- F 2 s
0V
0/230V
w1
-F1s
0/230V
230V
rt-sw
or-ws
gn-sw
U<48V
gn
Datum
I>0
rt
-A16
Plotdatum: 07.10.03
a
b
c
d
2
1
bn
gn-ws
X3
3
2
rt-sw
rt-sw
ME-UESW-4
1
+INV-A9s-X1:1/4.2
+INV-A9s-X1:2/4.2
+INV-A9s-X1:3/4.2
+INV-A9s-X1:4/4.2
+SQ-A21-X6:3/7.2
+SQ-A21-X6:4/7.2
Erdungsschraube
+SQ-T2m:0V/5.1
+INV-A4-X2:4/4.7
+INV-A3s-X9:1/6.6
or-ws
or-ws
5A
1A
1A
2A
1A
1A
1A
1A
1A
+SQ-T2m:400V/5.1
+INV-A4-X2:1/4.7
+INV-A3s-X9:2/6.6
1A
- F 3 s 10A w3-0V
Gleichrichter/
rectifier
IGBT
4A
Lüfter/fan
2
Wasserp./pump
400V
bl
gr
br
1
schw
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Änderung
Datum
+SQ-T2m:w5-0V/5.1
+SQ-T2m:w5-9V/5.1
gn
9
Name
ws-sw
ws-bl
ws-bn
ws-rt
1
g n - s w2
3
4
1
gn
gn
gn
gn
X4
10
rs
Datum
or
Name
bn
1
Konrad
ws
vio
08.01.01
ge
Master Balance
rt
rt
rt
rt
Slave Balance
X6
gepr.
gez.
1
X5
gn
1
2
3
4
1
2
3
2
ws 3
10
4
4
12
+OP2
-K1
/9.7
5
gn-sw
gn-sw
+SQ-T2m:w4-0V/5.1
Plotdatum: 07.10.03
a
b
c
d
6
8
gn-ws
gr-sw
rt
ws
gn
Flachbandkabel/flat band cable
+SQ-T2m:w4-18V/5.1
+SQ-A16-X4:7/6.2
+INV-A3m-X6:7/5.4
+INV-A3s-X6:7/6.4
+INV-A3s-X6:8/6.4
+SQ-A16-X5:1/6.2
+SQ-A16-X5:2/6.2
+SQ-A14-X3:1/8.5
+INV-A3s-X1/6.6
+INV-A4-X1/4.7
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
20
1
2
3
4
1
2
3
4
1
2
3
4
X6
16
1
X9
X4
+15
BT
GND
1
X3
-A11
1
UESW
2
3
3
MTC
X1
WR
Slave
X7
4
4
rt
rt
rt
rt
1
ge
1 9
6
X8
1
1
X5
X11
X1
X12
4 3 2 1
X10
X2
34
1
6
I
J
F
G
E
F
X3
D
E
C
D
B
C
S
A
B
4
-X6
E
A
4
+SQ-A14-X1/8.5
X5
A
-A13
3
3
7
1
2
ein
2
3
3
X2
2
2
torch
switch
2
BT2
4
4
oder/
or
torch
switch
1
BT1
1
1
1
2
3
Auftragsnr.
Zeichnungsnr.
Insquare 600 AC-DC
Projektbez.
S
9
Blatt
=
+ SQ
Doppelseitiges
Schweissen aus
Option: Doppelseitiges Schweissen/
option: welding two sides
3
1
rt
+OP1
-S3
5
5
8
Brenner mit Doppeltaster
oder mit Brennerpoti/
torch with 2 button
or with torch poti
-X5
+OP1
-X4
1
2
ME-BT-1.5
sw
Fußfernregler/
foot remote control
G
H
ge
ws
H
I
+SQ-A14-X2/8.6
K
X1
TOUT
TIN
AGND
Poti Fern/remote control
Fußt/switch foot pedal
TIG/BT2/torch switch 2
TEST
BT/torch switch
REF50
X4
sw
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
Steuerstromkreis
flat band cable
Flachbandkabel/
Flachbandkabel /
JP2
1
X15
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
10
ME-MTC/T-1.5
1
-A12
X2
4 3 2 1
4 3 2 1
1
rs
Anpassung
Spannungsanzeige/
adjust voltage
display
X13
10
5
+INV-A3m-X1/5.5
vio
Ferittring 3 Wdg.
ferritt ring 3 turns
6
+OP2-X7:4/9.2
+OP2-X7:3/9.2
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
26
X14
5
5
34
Störung
Master
2
34
I>0 Master
ME-MTC-1.2
Poti Fern
Fußschalter
BT2-Pilot ein
+5V
X1
1
-A21
Start
X2
I>0 Slave
Master
1
X3
34
4
Flachbandkabel/flat band cable
Slave
3
GND
2
ME-I-SDVT-1.1A
Flachbandkabel/flat band cable
1
1
BT. Poti
ge
1
7
Bl.
E
A
Brennerpoti/torch poti
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
Plotdatum: 07.10.03
a
b
c
d
Änderung
HOLD
gn
Datum
<48V
RMS
S TEST
U
gn
Störung/
failure
rt
Übertemperatur/
overtemp.
ge
NETZ/
main
gn
1
Name
gepr.
gez.
08.01.01
Datum
PROGRAMM-NR.
-A14
2
Konrad
Name
Hz
S
A
kHz
Hz
S
V
A
3
1
1
2
4
6
7
8
ANSTIEG/upslope
STROM/current I1
ANSTIEG/
upslope
gn
20
X1
TIG-ELEKTRODE O mm
AC FREQUENZ/frequency
AC BALANCE + (%)
ZEIT t2/time t2
STROM I2/current I2
GAS:VORSTRÖMEN/preflow
ZÜNDIMPULS/ingniton pulse
1
10 11 12 13 14 15 16
X3
9
STARTSTROM/initial curr.
STARTSTROM/
initial curr.
gn
5
gn
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
3
4
16
DISPLAY: SPANNUNG/voltage
GAS:NACHSTRÖMEN/postflow
X2
1
2
JP8
4
JP7
+
+
+
-
5
6
TIG
JP6
7
8
X5
JP5
~
~
JP4
JP3
JP2
+SQ-A11-X3/7.3
+SQ-A11-X14/7.4
Auftragsnr.
Zeichnungsnr.
Insquare 600 AC-DC
Projektbez.
Flachbandkabel 20pol./flat band cable
JP1
9 10 11 12 13 14 15 16
7
ME-TF-1.2
Elektrode
ENDSTROM/
final current
3
Flachbandkabel 26pol./flat band cable
1
Frontplatine
26
STROMNACHREGELUNG/arc force
HOTSTART-STROM/current
HOTSTART-ZEIT/timer
6
ABSENKUNG/
downslope gn
gn
PUNKTZEIT/timer spot welding
ENDSTROM/final current
ABSENKUNG/downslope
ZEIT/time I1
I2/t2
gn
Abschaltung Pilot 20-30 min
bei max keine Abschaltung/
pilot off after 20-30 min
pilot infinite
P1
+SQ-A21-X5:4/7.2
I1/t1
gn
P2
5
9
Blatt
=
+ SQ
TEST, PROG
GASTEST
2-TAKT
I2 (%)
4-TAKT
FUSSFERNR. I1
HANDFERNR. I1
BRENNER I1
MASCHINE I1
LIFT-ARC
HF
0
PUNKTEN
PULSEN SCHNELL
PULSEN LANGSAM
0
8
8
Bl.
Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet
I>0
3
8
Änderung
4
Datum
Name
Datum
30.03.01
gepr. 17.01.00
gez.
Siegner
.
Name
rt
vio
ws
bn
Automatik
Merkle
Schweißanlagen-Technik GmbH
Industriestraße 3
D - 89359 Kötz
Telefon 08221 -915 - 0
Telefax 08221 - 32596
rt
2
3
4
5
ge
or-ws
rt-sw
sw
6
or-sw
Hand
6
-K1
4
3
8
2
7
1
6
5
12
11
10
9
A2
A1
/7.1
/7.1
/7.1
Auftragsnr.
.2
.2
8
Zeichnungsnr.
10
9
.2
7
.2
6
.2
5
.2
4
.2
3
.2
9
Blatt
9
Bl.
=
+ OP2
STROMPFAD
-X7
+SQ-T2m:w3-42V/5.1
2
1
8
+SQ-T2m:w3-0V/5.1
PIN-NR.
vio-ge
vio-ws
Not-Aus Relais
emergency stop relais
7
Insquare 600 AC-DC
Projektbez.
+SQ-A11-X7:6/7.4
+SQ-T2s:230V/6.2
+SQ-T2s:0/230V/6.2
+SQ-A11-X7:3/7.4
Trennverstärker
isolating amplifier
vio-ge
1
Automatenanschluß
3+
74
8
230V/AC
Output
-A18
1+ 9-
bl
+SQ-A8-X6:2
Input
+INV-A3m-X8:8/5.6
+SQ-K1:7
5
-S1
+INV-A3m-X8:7/5.6
Ferritring 3Wdg.
ferrit ring 3 turns
Leitspannung/control voltage
Leitspannung/control voltage
7
5
Not-Aus Insq./emergency stop Insq.
Not-Aus Insq./emergency stop Insq.
6
--> Schweissen ein/welding on
--> Schweissen ein/welding on
3
4
<-- Lichtbogen I>0/arc I>0
<-- Lichtbogen I>0/arc I>0
2
1
-X7
Nur bei Option Leitspannung
only at option control voltage
Leitspannung 0...10V
Not-Aus Schleife
Plotdatum: 07.10.03
a
b
c
d
2
Option:
Automatenanschluß/
machine welding connection
Schweissen ein
1
18. EU-Conformity Attestation INS 300-420
EU – Conformity Attestation
Description of the unit:
TIG Welding Unit
Model:
Insquare W 420 DC,
Insquare W 420 AC/DC,
Insquare W 300 DC
Insquare W 300 AC/DC
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
EN 60204 - 1 / IEC 204 - 1 / VDE 0113 part 1
EN 60974-10 / VDE 0544 part 10
Kötz, April 19 th, 2004
Wilhelm Merkle, Generalmanager
Merkle Schweissanlagen-Technik GmbH
69
19.
EU-Conformity Attestation INS 600
EU – Conformity Attestation
Description of the unit:
TIG AC-DC Welding Unit
Model:
Insquare W 600 AC-DC
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
EN 60204 - 1 / IEC 204 - 1 / VDE 0113 part 1
EN 60974-10 / VDE 0544 part 10
Kötz, April 19 th, 2004
Wilhelm Merkle, Generalmanager
Merkle Schweissanlagen-Technik GmbH
70
Notes:
71
MERKLE
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
Technical changes reserved
July 13th, 2004
72
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