ESAB MXL 200 User manual

Instruction manual

0459 560 101 GB 20170322

MXL™150v,MXL™200,

MXL™270,MXL™340

TABLE OF CONTENTS

0459 560 101 © ESAB AB 2017

1SAFETY ......................................................................................................... 4

1.1 Meaning of symbols ................................................................................. 4

1.2 Safety precautions ................................................................................... 4

2INTRODUCTION............................................................................................ 7

3SHIPMENT AND PACKAGING ..................................................................... 8

4TECHNICAL DATA ........................................................................................ 9

5OPERATION .................................................................................................. 10

5.1 Fitting the liner.......................................................................................... 10

5.2 Assembling the swan neck ..................................................................... 10

5.3 Fitting the central adaptor assembly to the equipment........................ 11

5.4 Setting the level of shielding gas............................................................ 11

5.5 Checklist ................................................................................................... 11

5.6 Changing wire........................................................................................... 11

6MAINTENANCE............................................................................................. 12

6.1 Overview ................................................................................................... 12

6.2 Cable assembly ........................................................................................ 12

6.3 Cleaning the wire feed ............................................................................. 12

6.4 Spiral liner / PTFE liner ............................................................................ 12

6.5 Cleaning the swan neck........................................................................... 13

7FAULT-TRACING........................................................................................... 14

8DISASSEMBLY AND DISPOSAL.................................................................. 15

9IN THE EVENT OF AN EMERGENCY .......................................................... 16

10 ORDERING SPARE PARTS .......................................................................... 17

ORDERING NUMBERS........................................................................................ 18

SPARE PARTS LIST............................................................................................. 19

WEAR PARTS....................................................................................................... 21

ACCESSORIES .................................................................................................... 23

Rights reserved to alter specifications without notice.

1 SAFETY

0459 560 101 -4- © ESAB AB 2017

1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!

Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!

Means potential hazards which could result in personal injury or loss of

life.

CAUTION!

Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual

and follow all labels, employer´s safety practices and Safety

Data Sheets (SDSs).

1.2 Safety precautions

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety

precautions must meet the requirements that apply to this type of equipment. The following

recommendations should be observed in addition to the standard regulations that apply to

the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the

equipment. Incorrect operation of the equipment may lead to hazardous situations which can

result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

○ its operation

○ location of emergency stops

○ its function

○ relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorised person is stationed within the working area of the equipment

when it is started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

1 SAFETY

0459 560 101 -5- © ESAB AB 2017

4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions

when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or

wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding.

EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to

EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your

body between the torch and work cables. Never coil the torch or

work cable around your body. Keep welding power source and

cables as far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases

away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens

and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY

0459 560 101 -6- © ESAB AB 2017

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only

qualified people remove covers for maintenance and troubleshooting as

necessary. Reinstall panels or covers and close doors when service is

finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure that there are no inflammable

materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

Class A equipment is not intended for use in residential

locations where the electrical power is provided by the

public low-voltage supply system. There may be potential

difficulties in ensuring electromagnetic compatibility of class

A equipment in those locations, due to conducted as well

as radiated disturbances.

NOTE!

Dispose of electronic equipment at the recycling

facility!

In observance of European Directive 2012/19/EC on Waste

Electrical and Electronic Equipment and its implementation

in accordance with national law, electrical and/or electronic

equipment that has reached the end of its life must be

disposed of at a recycling facility.

As the person responsible for the equipment, it is your

responsibility to obtain information on approved collection

stations.

For further information contact the nearest ESAB dealer.

ESAB has an assortment of welding accessories and personal protection equipment

for purchase. For ordering information contact your local ESAB dealer or visit us on

our website.

2 INTRODUCTION

0459 560 101 -7- © ESAB AB 2017

2 INTRODUCTION

The MIG / MAG welding torches of this series are exclusively intended for shielded- arc

welding using inert gas (MIG) or active gas (MAG) for industrial and commercial use by

suitably trained employees. The torches are only available in manual versions.

3 SHIPMENT AND PACKAGING

0459 560 101 -8- © ESAB AB 2017

3 SHIPMENT AND PACKAGING

The components are carefully checked and packaged however damage may occur during

shipping.

Checking procedure on receipt of goods

Check that the shipment is correct by referring to the shipping note.

In case of damage

Check the package and components for damage (visual inspection).

In case of complaints

If the package and/or components have been damaged during shipment:

• Contact with the last carrier immediately.

• Keep the packaging (for possible inspection by the carrier or supplier, or for returningn

the goods).

Storage in an enclosed space

Ambient temperature for shipment and storage: -25°C to +55°C

Relative air humidity: up to 90% at a temperature of 20 °C

4 TECHNICAL DATA

0459 560 101 -9- © ESAB AB 2017

4 TECHNICAL DATA

Welding torch MXL 150v MXL 200 MXL 270 MXL 340

Type of cooling Air Air Air Air

Permitted load at 20% intermittence *

Carbon dioxide CO2150 A

Mixed gas, Ar/CO2150 A

Permitted load at 35% intermittence *

Carbon dioxide CO2120 A 200 A 270 A 340 A

Mixed gas, Ar/CO2120 A 170 A 260 A 320 A

Recommended gas flow 8-15

l/min

10-18

l/min

10-18

l/min

10-20

l/min

Max pressure 2.5 bar

Wire diameter 0.6-0.8 mm 0.6-1.0 mm 0.8-1.2 mm 0.8-1.2 mm

Weight

2.5 m hose package 1.1 kg − − −

3.0 m hose package − 1.6 kg 2.2 kg 2.6 kg

4.0 m hose package − 2.0 kg 2.6 kg 3.7 kg

Cable assembly

Standard length 2.5 m 3.0 m / 4.0 m 3.0 m / 4.0 m 3.0 m / 4.0 m

Standard−control cable 2−pole 2−pole 2−pole 2−pole

* The capacity my be reduced up to 30% when pulse welding.

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or

cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F, or below.

General torch data with reference to IEC/EN 60 974−7

Type of voltage: DC voltage

Wire type: Standard round wire

Voltage measurement: Peak value of 113V

Connection protection equipment side (EN 60

529):

IP3X

Shielding gas: CO2or Ar/CO2

5 OPERATION

0459 560 101 - 10 - © ESAB AB 2017

5 OPERATION

General safety regulations for handling the equipment can be found in the "SAFETY"

chapter of this manual. Read it through before you start using the equipment!

CAUTION!

This product is intended for industrial use. In a domestic environment this product

may cause radio interference. It is the user's responsibility to take adequate

precautions.

MXL welding torches can be used in any welding position.

The torch switch in the MXL handle is suitable for 42 V, maximum 1 A.

5.1 Fitting the liner

Fit the correct wire guide liner for the application, as needed to suit the wire type and

diameter. See chapter "MAINTENANCE" section "Spiral liner / PTFE liner".

NOTE!

For information on how to install new liners and about correct assembly

procedure, see the chapter entitled “Maintenance”

Spiral liner = for steel wires

PTFE−liner = for aluminium, copper, nickel and stainless steel wires

5.2 Assembling the swan neck

The following figures indicate how to assemble the different welding torch types.

1. Gas nozzle 4. Tip adaptor

2. Contact tip 5. Gas diffusor

3. Nozzle spring

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