350mc3_e

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GLC 353/503/553 MC3Operating instructions

GLC 353 MC3GLC 503 MC3GLC 553 MC3MIG/MAG Welding Machine OPERATING INSTRUCTIONS

and SPARE PARTS LISTS

PLEASE KEEP SAFELY FOR FUTURE REFERENCE

128/01.01

CARL CLOOSSchweitechnik GmbHIndustriestr. 35708 HaigerTel. +49 2773/85-0Fax. +49 2773/85-275http://[email protected]

1GLC 353/503/553 MC3Operating instructions

Operating Instructions

MIG/MAG Welding Machine

GLC 353 MC3GLC 503 MC3

and

GLC 553 MC3with

CK 98 A Wire Drive Unit

Print No.: 128Issued: 01/01

Subject to technical alterations


W A R N I N G !

Prior to the first commissioning, all persons who are involved withthis machine should read this operating instruction manualcarefully and confirm that they have done so in writing.

Please keep the operating instruction manual easily accessible forall welders and service staff!

The best place is the welding machine itself!


EN50199:1995Appendix A (information)

Installation and useThe user is responsible for the installation and operation of the welding machine according to the manufacturer'sinstructions. If there is electromagnetic interference, the user is responible for finding a solution with the aid ofthe manufacturer of the welding machine, e.g. grounding of the weld current circuit, electromagnetic screeningand/or inlet filter.

A.1 Evaluation of the areaBefore installing the welding machine, the user has to evaluate any possible electromagnetic problems in thesurrounding area. The following must be taken into consideration:

a) Other mains supply lines, control lines, signal and telecommunication lines above, below and nextto the welding machine.

b) Radio and TV broadcasting station and receiver.c) Computer and other control units.d) Safety devices, e.g. protection for commercial equipment.e) Health of persons in vicinity, e.g. if using pacemakers and hearing aids.f) Units for calibration or measement.g) Resistance to interference of other equipment in the surrounding area. The user must ensure that

other equipment used in the vicinity is electromagnetically compatible. This may require additionalsafety measures.

h) The time of day when welding or other activities are being carried out.The extent of the surrounding area to be considered depends on the construction of the building and otheractivities which take place there and may exceed the boundaries of the property.

A.2 Procedure to reduce emissions

A.2.1 Mains supplyThe manufacturer recommends that the welding equipment is connected to the mains supply. Where there issome interference, additional safety precautions may be necessary, i.e. filter for the power supply.

A.2.2 Maintenance of the welding equipmentRegular maintenance intervals are recommended by the manufacturer.

A.2.3 Weld cablesWelding cables should be as short as possible and should be run close together on or near to the floor.

A.2.4 Potential equalizationThe electric connection of all metal parts in and near a welding machine should be taken into account. The metalparts connected to the workpiece may increase the risk of an electric shock if the welder touches these metalparts and the electrode at the same time. The welder should be protected against all connected metal parts.

A.2.5 Earth connection of workpieceIt must be ensured that earthing of the workpiece does not increase the risk of accident to the user or causesdamage to other electrical equipment.

A.2.6 ScreeningSelective screening of other cables and equipment in the vicinity may reduce electrical interference. Screeningof the complete welding equipment may be considered in special situations.

5/96


Safety specifications .......................................................................................... 7-9Particular information for welding .............................................................................. 7Technical data ............................................................................................. 9

General product description ................................................................................ 10

Operating instructions ................................................................................... 10-13Transport ........................................................................................... 10Mounting area, floor requirement, environment ..................................................... 10Storage ........................................................................................... 11Assembly ........................................................................................... 11Power supply ........................................................................................... 11Torch connection, earth cable ............................................................................... 11Shielding gas, reducing valve ................................................................................ 11Wire drive ........................................................................................... 12Coolant ........................................................................................... 12Commissioning ........................................................................................... 13

Special safety devices......................................................................................... 13Temperature protection ......................................................................................... 13Overload protection ........................................................................................... 13

Operation / Service ........................................................................................... 13

General instructions for shielded gas welding ............................................ 13-14Instructions for welding ...................................................................................... 15Operation......................................................................................B-1-44

Mechanical description ............................................................................... L- 1-24Illustrations welding machine GLC MC 3 .............................................................. 2-5Spare parts list GLC MC 3 .................................................................................... 6-7Illustrations wire drive unit CK 98 A ...................................................................... 8-9Spare parts list CK 98 A ........................................................................................ 10Sectional drawing: 2 + 2 roller system with central connection .............................. 11Spare parts list 2+2 roller drive compl. with central connectionfor steel and flux cored wire .............................................................................. 12-13Sectional drawing: 2 + 2 roller system with central connection .............................. 14Spare parts list aluminium equipment for 2+2 roller drive with central connection ..... 15HD Drive .......................................................................................................... 16Spare parts list HD Drive .................................................................................. 17-18Sectional drawing cable assembly for CK 98 A ..................................................... 19Spare parts list cable assembly CK 98 A............................................................... 20Sectional drawing cable assembly for CK 98 A, cable assembly connectable ...... 21Spare parts list cable assembly CK 98 A, cable assembly connectable ................ 22Sectional drawing wire coil holder compl. .............................................................. 23Spare parts list for wire coil holder compl. ............................................................. 24

Electrical description ................................................................................ L- 25-53Circuit diagrams GLC 353 MC 3 ....................................................................... 25-27Electrical parts list GLC 353 MC 3 .................................................................... 28-33Circuit diagrams GLC 553 MC 3 ....................................................................... 34-36Electrical parts list GLC 553 MC 3 .................................................................... 37-40Circuit diagram CK 98 A ........................................................................................ 41Electrical parts list CK 98 A .............................................................................. 42-43Circuit diagram CK 98 A with installation kit remote controller socket .............. 44-45Electrical parts list CK 98 A ............................................................................. 46-47Circuit diagram CK 98 A, cable assembly connectable ................................... 48-49Electrical parts list CK 98 A, cable assembly connectable .............................. 50-51Circuit diagram remote controller .......................................................................... 52Electrical parts list remote controller ...................................................................... 53

APPENDIXSupplement cooling water device .......................................................................... 51List of addresses - CLOOS representatives in Germany/abroad ..................... A1-A4

INDEX


Safety specifications

General information

Warning!This is a class A equipment which may cause radiointerferences in residential areas. In such a case theoperator may be asked to take adequate steps on hisaccount.

The GLC 353/503/553 MC3 machine with CK 98 A isbuilt according to EN 60 974-1. It corresponds to thelatest "state of the art" engineering and its reliabilityis proven. It must be operated by trained personnel inaccordance with the following instructions to providesafe and efficient operation.

The machine is not suitable for thawingpipelines due to Fire risk !Flammable gases or gases which induce a chemicalreaction, such as Acetylene, Propane, pure Hydro-gen, pure Oxygen are prohibited.

Please note the following!- Safety regulations VBG 15- Safety regulations VBG 4- Fire protection rules- Welding and maintenance to be carried out by

qualified personnel only.- The machine must be switched-off and

disconnected for all maintenance work.- Repair of electronics to be carried out by service

personnel only. If repair work is carried out byunauthorized persons and safety regulations arenot adhered to, the warranty becomes invalid.

This welding machine is intended for industrial useand must not be used in residential buildings.As >16 Amp are required per phase, this machine issubject to the IEC 61000-3-4 standard or EN 61000-3-12, when it is available. In order to avoidelectromagnetic interference (EMI), certain conditionsmust exist (size of mains impedance) for connectionto the public low voltage network. Please inform therelevant electricity supplier about this machinesconnection. Please do not hesitate to contact yourElectricity supplier or the manufacturer if you needhelp or information.

Particular information for welding

Personal protection (rays, gases, vapours) When welding, dry protective clothing, apron,

helmet and gloves as well as solid work shoesshould be worn.

Use a protective shield or helmet with glass, withDIN marking, outside clear, inside tinted.

Protect other persons in the vicinity of thewelding area from UV rays and spatter bysuitable, non-flammable partition walls.

Always wear safety glasses if you are in an areawhere welding takes place.

Wear safety glasses with side protection whenyou are welding or when removing slag.

Caution! UV rays are released during welding.Protect body and particularly the eyes. Keepprotective ointment and eye drops available.

All metal vapours are toxic! Be careful withalloys which contain lead, cadmium, copper,zinc, nickle, chrome, berillium.

Parts, cleaned with chlorinated agents, cause thetoxic gas phosgen to form in the arc.Caution Risk of poisoning in narrow places !If shielding gas hoses are not tight or theshielding gas valve gets caught unintentionally,shielding gas may escape to such an extent thatthe oxygen content of the inhaled air decreases;symptoms of poisoning appear which may lead tounconsciousness and suffocation. Sufficient freshair must be provided! Please check the gassupplying parts at regularintervals.

Fire prevention (explosion) Remove all flammable materials around the

welding place or cover these with a non-flammable material.

Hot slag or spatter might cause fires if in contactwith flammable materials.

Only use shielding gases suitable for welding,such as Argon, CO2 and Argon and CO2 orArgon, CO2 and O2 mixtures.Never use flammable gases like Acetylene,Propane, Hydrogen or fire supporting gases suchas Oxygen.

Never weld on drums, tanks or similar containersunless they have been thoroughly cleaned andyou are sure that no toxic, flammable or explosi-ve vapour can develop.

Fire fighting agents such as water or sand or afire extinguisher should always be available.

Confined spaces must have a free passageallowing escape in case of danger.

Please observe the weld area and itssurroundings when welding has finished. Firemay break out later due to smoldering.

Electrical danger (current, voltage)

PacemakersWearers of pacemakers may potentially by at riskfrom arc welding. When MIG/MAG welding the risk isfrom magnetic fields and when TIG welding from highvoltage pulses of the arc ignition units.


As there are several versions of pacemakers, thesituation must be clarified with the relevantpacemaker manufacturers or their representatives(hospital etc.).

Switch off the welding machine when not in useto prevent any electrical risk.

Warning! The terminal voltage of the weldingmachine may be up to 113V= or 48V~!

If you have to stand on metal or in a wet areaduring welding, insulation with suitable drymaterials is required.

Avoid contact with wet or conductive metal parts;wear dry clothing.

Always maintain correct insulation of cables,plugs and welding torches. Do not overloadthese parts.

Keep everything dry, including clothing, weldingarea, cables and welding machine. Repairimmediately any faulty water cooling lines.

Welding machines may only be used if all coversare present and correctly installed.

Although the machine is marked S (approvedfor welding in environments with increasedelectrical hazard), the power source itself maynot be installed here, because of the mainsvoltage of 400 V; only the welding torch and thewire drive unit are permitted at such places.

Before any work is carried out inside the powersource, the mains switch must be switched-offand the mains plug disconnected.

After disconnecting the mains plug, wait at least2 minutes until the capacitors have reached safevalues.

Be careful when changing the wire coils. Switchoff the machine so that the switching commandcannot be initiated.

Lock the wire coil holder, by turning the lockingbutton to prevent the wire coil becoming loose.


Technical data:GLC 353 MC3 GLC 503 MC3 GLC 553 MC3

Input:Nominal input voltage 3x400V ac 3x400V ac 3x400V acNominal frequency 50Hz 50Hz 50Hz(Other voltage and 60 Hz frequency are available upon request)Input - peak current 23A 37A 47AInput - continuous current 19A 27A 40ASlow blow fuse 25A 35A 50APower supply cable 4x4mm2 4x6mm2 4x10mm2Input constant power 13.1kVA 18,7kVA 27,7kVAPower factor cos Phi 0.92 0,96 0,96

Output:Max. open circuit voltage 56V 70V 70VWelding range for MIG/MAG 40A/15V-350A/40V 40A/12V-500A/42V 40A/12V-550A/44,5VDuty cycle 100% 300A/29V 400A/34V 500A/39VDuty cycle 60% (10min.) 350A/31.5V 500A/39V 550A/41,5VType of protection IP 23 IP 23 IP 23Type of cooling F F FInsulation class F (1550C) F (1550C) F(155C)Dimensions LxWxH power source 960x460x930mm 1190x530x930mm 1190x530x930mmWeight of power source 153kg 220kg 220kgDimensions LxWxH wire drive unit 610x380x355mmWeight wire drive unit 22kgTorch water cooling 2.0 l/min. at 3.0 bar (30m Ws)Continuous noise level 1 m a height of 1.6 m and a distance of 1 m from the machine:Machine noise when switched on 58 dB (A) 60 dB (A) 68 dB (A)Arc noise at max. output 80 dB (A) 82 dB (A) 85 dB (A)according to DIN 45 635, part 1Wire feed infinitely adjustable 0 ... 24m/min. 0 ... 30m/min. 0 ... 30m/min.Permission EN 60 974-1

The machine is designed for manual MIG/MAG welding of all metals.Manual DC-current TIG welding with lift-arc ignition is possible.All coated stick electrodes can be welded.

- The machine corresponds to the machine rules (98/37/EG), the low voltage rules(73/23/EWG) and the rules for electromagnetic compatibility(89/336/EWG).

- The machine is approved for welding in environments with increased electrical hazard and is marked withthe letter S.

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Shielding gases

The following gases are used for MIG/MAG welding:Pure Argon, CO2, mixtures of Argon and CO2 orArgon, CO2 and O2.

Flammable gases or gases which induce a chemicalreaction such as Acetylene, Propane, pure Hydro-gen, pure Oxygen are prohibited.

Operating instructionsTransport

The machine must always be transported withoutgas cylinder.All cables must be wound up and put on the machinebefore transport.The machine can be moved on its wheels. Whenusing a fork lift truck, the forks must be appliedbetween the wheels. The machine must liecrosswise on the truck.Transport by means of a crane is also possible. Ifjack rings are available all of them must be usedbecause of the carrying capacity and loaddistribution. If there are no jack rings, two belts mustbe used, pulled crosswise under the machine insidethe wheels.

Mounting area, floor requirement,environment

- The machine should be installed on a horizontal,flat surface, dust-free and well ventilated.

- The distance between other machines orbuildings should at least be 0.50 m (24 inches onall sides, to aid ease of servicing.

- The cooling air entrance and exit grills must notbe restricted in any way

- The ambient temperature may vary from -100Cto +400C .

- The machine is protected to IP 23 which doesnot permit use in the rain. If necessary, it shouldbe covered. In this case ensure that the coolingair flow is not affected!

- The machine is marked "S", which meansapproved for welding in environments withincreased electrical hazard; however, the powersource itself must not be installed there due tothe mains voltage of 400 V; only the weldingtorch is permitted in such places.

General product descriptionApplication possibilities andrestrictions

The transistorized MIG/MAG pulsed arc weldingmachine type GLC 353/503 MC3 with wire drive unittype CK 98 A is a welding machine with micro computercontrol and a new air cooled power part with extremelyquick regulation due to particularl switch controllertechnology. Outstanding welding features and low powerlosses result from this. Aimed drop deposition with ahighest possible spatter reduction when welding withArgon and Argon rich mixed gases with max. 20% CO2part. It can be welded pulse free with all arc kinds underArgon, Argon O2 mixed gases with multicomponentmixed gases and under pure CO2.

Remarkable features of the wire drive units are theprecise rotation control (tacho control) and high motorpower (100 W) with four quadrant regulation (D).

2 + 2 roller system and 4 roller system guarantee safe,slip-free and low abrasion wire transport. The adjustmentof the counter pressure is reproducible and comfortablein handling.

The arc burns between wire and workpiece undershielding gases (MAG = Metal active gas and MIG =Metal inert gas procedure).

The wire electrode continuously unwound off the reeluntil a reel is used up. The coil weight is 15 kgs withsteel and 4 ... 5 kgs with Aluminium.

The wire thickness and welding torches to be useddepend on material thickness and seam shape.

Power sources and wire feed are in separate housingsconnected by a cable assembly. The complete systemis mounted on four rubber tyred wheels.

The machine is connected to a three phase currentsupply. Direct current is available at the outlet.The machine is set up for manual, mechanical androbot MIG/MAG welding all metals. Manual d.c. TIGwelding with lift-arc ignition is possible.The machine is suitable for welding all kind of flux coredwire electrodes.

The machine is not suitable for thawing pipelines.- Fire risk! -

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Storage

- The machine should be stored indoors at atemperature between -100C and +400C andshould be covered.

- If the coolant is not emptied, please ensure thatan anti-freeze agent is added. The coolant mustbe disposed of and must not enter the maindrainage system.

Assembly

A complete machine comprises: 1. Transistorized MIG/MAG pulsed arc

welding machine typeGLC 353/503MC3

2. Wire drive unit type Typ CK 98 A 3. Cable assembly, connectable 4. MIG/MAG welding torch 5. Standard accessories including:

Earth cableReducing valve with l/min.-scaleToolsSet of fuses for power source

6. Options, if required

The individual components, MIG/MAG weldingmachine, connectable cable assembly, wire driveunit, gas cylinder and reducing valve have to beassembled. The water hoses must not beexchanged. The flow is marked blue!

Make sure cooling liquid is sufficiently filled.All water-cooled machines are supplied with a 5 litrecontainer of ready-to-use mixture.

Power supply

The power supply must be installed by qualifiedpersonnel only!Please ensure that the mains voltage to be used isidentical to the operating voltage indicated on themachine type plate.

According to the connection regulations the machinehas to be connected by means of a mains cable. Thepower supply must be fused according to theconnection regulations. To ensure good weldingperformance the cross section of the connectioncable must be adequate.

The phases L1, L2, L3 and PE are connected. Theneutral wire (N) remains free.A correct conductor connection must be provided!(VDE regulations).

Torch connection, earth cable

- The welding torch is connected to the centralconnection, item 13, the water hoses to theconnections items 119 and 120 - they must notbe exchanged (insufficient cooling of the weldingtorch). The flow is marked blue. The control line isconnected to the socket, item 109.

- The earth cable is connected to the currentconnection, item 79, and locked by turning right.

- The gas cylinder is placed on the base plate, item87, at the rear of the machine and is secured by achain, item 87/2, which is connected to theholder, item 87/1.

Shielding gas, reducing valve

The reducing valve is screwed onto the gascylinder and connected to the machine by meansof the gas hose, item 215. The gas quantity isadjusted at the reducing valve. For this purposethe machine must be switched on and the torchbutton or key gas manual, item 103 must beactuated at the wire drive unit.

The normal gas quantity for Argon and mixedgases is 8 - 15 l/min. and for CO2 10 - 20 l/min.

In general, carbon dioxide with a percentagepurity of 99.9 % is used for welding withunalloyed or low alloy steels with a strength of 37- 60 kgs. In Germany the gas cylinders have theadditional marking S (= Schweizwecke -welding purposes).These steels can be welded with the gas mixture(AR + CO2 + O2), high alloy steels, e.g. chromenickel steel require protective gas K2 ( Ar + 2%CO2). Aluminium and other nonferrous metalsrequire pure Argon 99.9 %.

The flow quantities indicated on the extractionmanometer depend upon choke setting, item113/2 in front of the gas valve, item 111. Thischoke has a nominal diameter of 0.6 mm. Thenominal diameter size 0.6 is clearly marked onthe litre scale of the extraction manometer. Forexample, in the case of 4 bar, the flow quantity is11.5 l/min.

In the case of ring mains which operate at lesspressure, it is not possible to set a flow quantity

12


of 11.5 l/min. In this case the choke diameter hasto be enlarged from 0.6 to 2.0 mm or the gasretaining unit, item 113 exchanged for item 113 a,so that a greater flow is created at a lowerpressure.

If the original flow meter is not connected, theflow quantity at the gas nozzle of the weldingtorch must always be checked with a suitableflow meter.

A simple gas flow measuring tube is availableunder ref. No. 097 03 04 00.

Wire drive

Wire drive rollers, item 18, wire guide unit, item 10 andwire inlet nozzle, item 15 are marked according to thewire size, to prevent wrong nozzle size being used bymistake. This also applies to the contact tips and linersof the welding torch, which are also marked with thewire sizes.

When changing the wire drive rolls and gear wheels,force must not be used to mount them on the gearshafts, e.g. hammer or similar because this mightcause damage.Prior to installation, all parts must be cleaned and -except the drive rolls - be greased.

The welding wire itself is threaded inside the wire driveunit throughout the wire guide spiral, item 12, the wiredrive rollers, item 18, the wire guide piece, item 10, andthe wire inlet nozzle, item 15. The wire is transported tothe torch by actuating the torch button wire manual,item 104 on the wire drive unit. To do this the machinemust be switched on. The pressure arms, item 7 anditem 8 must only be sufficiently pressed against thepressure units as is necessary for the relevant wire typeand size. The adjustment is reproducible. The pressurearms swing out for threading the wire or exchanging thewire drive rollers. The two pressure units, item 9, haveto be adjusted equally.The pressure units of the pressure roller bracketsmust not be set at more than -3-

The brake of the wire coil holder can be adjusted withthe tightening screw, item 8. The wire coil should notmove when the motor brakes, to prevent wire windingsfalling off the coil and kinking or short circuits occurring.

If the brake no longer works, the brake disk, item 7 mustbe replaced!

The wire coil must be secured on the wire coil holderwith the locking button, item 2, to prevent it falling off.

Coolant

As soon as the welding torch is connected, the coolantcan be filled into the cooling system. It is absolutelyessential that distilled water is used! Do not usechlorinated water or water with a high mineral contentbecause of its electrical conductivity. The cooling systemcannot be completely emptied. Therefore, to avoiddamage from frost, an anti-freeze agent must alwaysbe added, which also protects against corrosion. Onlyuse Glykorol EL. CLOOS ref. No. 000 01 01 22!

A five litre container of a ready-to-use mixture of: twoparts distilled water and one part Glykorol EL(up to - 20 C) is supplied with each water-cooledmachine. CLOOS ref No. 000 01 01 31.

The water container is filled via filling connection,item 86. A certain vacuum must remain so that thecooling liquid can return during water blow throughwithout overflowing. The drain cock, item 93, at therear of the machine must then be opened until thecoolant flows out. The water pipes are therebyvented and coolant is brought to the pump.

WARNING! Avoid dry-running of the pump, evenfor a short period! Otherwise the shaft seal maybe damaged.

With regard to the construction of the pump it isimportant that the cooling liquid is absolutely clean.Impurities such as sand or swart as well as stickyresidues, lubricating grease etc. may damage thepump.Be careful after torch repairs !

Danger! Glykorol ELis dangerous if swallowed andharmful to skin! Carefully washyour hands after filling!!Safety precaution!Keep out of reach of children.

The water hoses are filled when the machine runs.When using very long cable assemblies, the resultingloss of water in the cooling water container must bereplenished. Please note the max. coolant quantity!

13


Special safety devices

Temperature protectionThe main transformer, main rectifier andtransistor cascade are protected fromoverheating by thermal switches which cut offthe welding command. This is indicated by ayellow control lamp and as plain text on thedisplay. The machine should remain switchedon so that cooling air can continue cooling.

Overload protectionThe cooling fan and water cooling pump areprotected from overheating by thermalswitches. Overheating can be caused byovercharging the motor windings. The thermalswitches cut off the welding command and thetension from the motor winding. This isindicated by a yellow control lamp and as plaintext on the display.Switch the machine off and eliminate thecause for overheating.

Service

The machine can be commissioned when thewelding machine, cable assembly, wire drive unit,welding torch, earth cable, shielding gas cylinder withreducing valve and welding wire have correctly beenconnected and installed.

- It should be ensured that the flow and returnwater hoses of the wire drive unit and the torchare not mixed up (insufficient torch cooling). Theflow is marked blue.

- The cable assembly must be protected fromtension on the power source with the enclosedhose clip on the upper part of the cylinder holder.

- The cable assembly must be protected fromtension of the wire drive unit at the baseplate withthe second hose clip.

The tank cap must always be screwed down toprevent contamination of the cooling liquid!

The welding machine must always be switched offwhen the torch cooling circuit is interrupted, forexample when the welding torch is removed. 'Thewater connections then shut automatically to preventthe coolant running out. The pump produces adynamic pressure of 3,8 bar. If this pressure existsfor a long period, the pump and the coolant heat upto such an extent that damage and leakages mayoccur.

WARNING!The machine is provided with a water filter in front ofthe suction side of the cooling water pump.When the message "lack of water" occurs, this filtermust be checked for impurities, be removed, washedand reinstalled.Do not change the mounting direction! Arrow headaway from pump ! Do not install a water filter withouta flow control switch.

Water cooling deviceWhen welding at high ambient temperature (greaterthan 40C) with high capacity (greater than 500 A)it is recommended that the cooling water for thetorch is cooled by a separate water cooling device,i.e. ST 157/2. This device prevents the ambient airbeing warmed up by the components which arebeing cooled, as is the case with an integratedwater cooling system.

Commissioning

The machine is switched on with the mains switch,item 42.Pum and fan are switched on after approx. 10 s for 1minute. The cooling air is suctioned at the front sideand blown out at the rear side (gas cylinder).

Interval switch off for pump and fan!Pump and fan are only switched on when welding.After welding they run for approx. 5 more min. inorder to recool accordingly. This avoids that in thecase of longer downtimes dirty cooling air is suckedinto the machine. Furthermore, noises and currentconsumption are reduced.The GLC 553 MC3 fan is provided with two powersteps. Normally, the low step I is switched on. Ifcooling is not sufficient, the stronger step II can beused.

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General instructions for shielded gaswelding

With MIG/MAG shielded arc welding machines bothshort arc and spray arc can be used.

Short arc is also called dip-transfer arc. When usingthe short arc procedure, there is a relatively low weldingdensity on the welding wire so that the additionalmaterial passes on to the workpiece in the shape ofindividual drops (approx. 50 - 80 drops per second).The heat input itself is relatively low so that with thismethod thin sheet as well as root and vertical up seamswith thicker plate can be welded (also awkward positionwelding).

With the spray arc technique a high current density isused on the wire cross section. The welding material nolonger passes in drops onto the workpiece but as aspray. Wherever an adequate welding performance asregards the fusion quantity is required, the spray arcprocess is the only one to consider.At less than approx. 180 Amps/mm2 current densitywith steel wire short arc welding is generally considered,whereas with more than 200 Amps/mm2 the spray arctechnique starts to be used. The transition from shortarc to spray arc varies according to the different kind ofgases.Using CO2 as shielding gas, deep penetration is afeature with steel welding, whereas, Argon S 5 (Ar +5 % O2) for example gives only slight penetration. Usinggas mixtures (normal ratio about 90 % Ar + 5 % CO2 +5 % O2) penetration lies somewhere between the twoabove gases.

Due to the deep penetration when using CO2, thewedge angle must not exceed 30 - 40. Less weldingmaterial is therefore required on the one hand and onthe other, the welding efficiency is increased.

In the case of thin sheet, up to 3 mm maximum, thevertical down seam position is advisible, as this resultsin a higher welding speed and the surface appearanceof the seams is also improved.High alloy steels are welded using protective gas K2 (Ar+ 3% CO2).Non-ferrous metals such as aluminium, copper, bronze,etc. are welded with pure Argon 99.9% or gas mixturesconsisting of Argon and Helium (65 % Ar + 35 % He).

In the case of copper welding it is also necessary topreheat the workpiece from 4 - 5 mm thickness upwardsto coat the welding edges with a deoxidizing paste.During welding the welding torch must be held at anangle of 5 towards the vertical of the workpiece. Thetip is approx. 15 mm away from the workpiece wirediameter.

Special instructions for pulsed arcwelding

Spray arcUsing Argon or Argon mixtures with less than 20% CO2and sufficient high power and voltages the materialtransition is carried out freely in the form of small dropsor drop chains without short circuit formation. Thereforea spatter free welding is possible with the spray arc. Aprecondition is, however, the use of the above shieldinggases. Due to the high energy input and the highdeposit efficiency this technique is only used - similar tothe semishort circuiting arc weldment - for the filler andcover pass welding in the w- and h-position.Pulsed arcThe short-circuit free material transition of the spray arcis made use of by the pulsed arc technique. The energysource switches periodically to a higher pulse current,which makes an aimed and well controllable materialtransition possible, while the base current serves forthe ionization of the arc distance and the preheating ofthe wire electrodes end and the material surface. Bymeans of these current pulses a free material transitionin the rhythm of the pulse frequency is achieved.This technique allows a good mastery of the moltenpool, which is very important for out-of position welding.Due to the high pulse currents in the case of small basecurrents relatively thick electrodes can be used.

The working range in the pulse technique is restrictedto the min. or max. current capacity of the wire electrodeused.

The disadvantage of the complicated adjustment of thewelding process (max. 5 parameters) is compensatedin case of an aimed variation of the welding parameters.Therefore the degree of dilution in case of depositwelding is for example kept small, or when selecting amaterial transition with one drop per pulse withcorresponding drop size a virtually spatter-free weldingis achieved.

The correct pulse current adjustment is achieved whenthe wire end can be seen as tip in the arc.

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Instructions for welding

Non-coppered welding wires, aluminium and specialsteel wires tend extremely to stick to the current tip inthe welding torch. Especially in the case of thin wires,it often becomes necessary to take peak currentlimitation measures for the ignition from the powersource, measures which can be supplied optionally.The software in the GLC ....MC3 machines automaticallysets this peak current limitation, if required.In the case of special steel wires a plastic core must beinstalled in the welding torch, as this is basically requiredfor aluminium. In metal spirals are being producedscorching points which considerably affect the wirefeed.

When MSG (metal shielded gas) welding the weldingwire is charged with the potential positive weldingcurrent whereas the power source minus pole is oftenconnected to the mains protective conductor via earthconnection.For this reason it is important that the welding wire in thewire drive unit, the wire drum and the wire dereeler orin its transport section does not touch the mains earthconductor or the counter potential negative weldingcurrent (welding compound).This kind of short circuit causes the weld result todeteriorate and may destroy components. There is arisk of fire due to the hot welding wire sections.

Index B-1

GLC 353/503 MC3

Operating InstructionsGLC 353/503 MC3

Index

E Introduction .................................................................................................. 3

B Operation ................................................................................................. 3-10

B1 Operating and display elements ................................................................. 3B1.1 Operating and display elements on the power source .......................... 4-7B1.2 Operating elements on the wire drive unit ................................................. 8B1.3 Working modes ............................................................................................ 9

B2 Welding ................................................................................................. 11-22B2.1 Procedure: MIG-MAG Normal 2 knob operation ................................. 12-13B2.2 Procedure: MIG-MAG Normal Synergic .............................................. 14-15B2.3 Procedure: MIG-MAG Pulse Synergic ................................................. 16-17B2.4 Procedure: TIG Direct Current ............................................................. 18-19B2.5 Procedure: Coated stick electrodes ................................................... 20-21

P Programming ........................................................................................ 23-34

P1 Operating elements for programming ...................................................... 23

P2 Program steps ........................................................................................... 24

P3 Operating modes when programming ................................................ 24-25

P4 Programming a weld procedure sequence ........................................ 26-31

P5 Calling up a weld procedure sequence ................................................... 32

P6 Correct a weld procedure sequence ........................................................ 32

K Configuration menu (Extension from software V1.56 up) ................. 32-34

IndexB-2

GLC 353/503 MC3

S Faults ..................................................................................................... 35-37

S1 Problems during operation .................................................................. 35-36

S2 System fault Overtemperature .................................................................. 37

W Maintenance .......................................................................................... 38-40

W1 Information, Intervals ............................................................................ 38-39

W2 Special instructions .............................................................................. 39-40

O Options .................................................................................................. 41-44

O1 Key-operated switch ................................................................................. 41

O2 Serial interface ........................................................................................... 41

O3 Remote controller ...................................................................................... 42

O4 Automation interface ........................................................................... 43-44

B-3

OperationGLC 353/503 MC3

E Introduction

The GLC 353/503 MC3 MIG/MAG power source with CK 98 A wire drive unit is adjustedwith regard to the arc capacity. You select the material, the shielding gas and the arcpower to be used and the processor, which is integrated in the power source, provides anoptimized arc based on the selected values. Ajustment is possible via the wire feed speed(or weld current) and arc length.

The power source enables programming of up to 50 welding processes (Jobs).

The first part of this operation manual informs you about the input elements and theprocedures required for welding.

The second part informs you how to program and call up the weld processes.

B OperationB1 Operating and display elements

The operating and display elements are on thefront plate of the

wire drive unit

and the

power source

B1 Operating and display elements

B-4

Operation GLC 353/503 MC3

B1.1 Operating and display elementson the power source

Front view power source

Operating and programming panel

Main switch

The operating and programming panel is subdivided into:

Display 1 Display 2

Operating modes

Signal lamps

Characterist iccurve selection

Programming

B1.1 Operating and display elements Power source

Display 3

B-5

OperationGLC 353/503 MC3Signal lamps:

The operation panel has two signal lamps:

- Start

- Temp (overtemperature)

Signal lamp Start indicates that the Weld signal was given.The signal can be given:

- via torch trigger- externally- in the operating mode E(lectrode) manual

Caution !Open circuit voltages exists on connection lugs P and N or onthe welding wire or electrode !

Signal lamp Temperature indicates that the operation temperature ofthe following components has been exceeded:

- Welding transformer- Welding rectifier- Transistor cascade- Cooling water pump- Fan

The welding process cannot be continued if the operating temperature of a component hasbeen exceeded. Restart is only possible when the overloaded component has cooleddown.

Display 1The following values are indicatedon the display:

- Welding voltage

- Wire feed speed

- Plate thickness

The value can be selected with the selector key. LED's show the values selected.

LEDs Selector key


B-6


Display 2 The following values are shownon the display:

- Weld current actual value- Weld current set value- stored weld current actual

value achieved during last weld(highest current output)

The value can be selected with the selector key. LEDs show the values selected.

Operation panel:

Press the selector key to selectthe required operation mode.The active operation mode isdisplayed by LED.The operating modes aredescribed under Definitions.

Press and hold the selector key formore than a second; the input modechanges and you can startprogramming (see chapterProgramming).

Operation panel programming:More

information is in theDisplay for operating sequence and weld process job No. chapter Programming

Key +10 (change value inincrements of 10)

Key Up

Key Down

Key Store

Diagram for programminga job sequence

LED's Selector key


Operating mode 2 cycle

Operating mode 4 cycle

Oper.mode Super 4 cycle

Operating mode spot weld

Operating mode program

Selector key

B-7

OperationGLC 353/503 MC3Operation panel characteristic curve:

On this panel the values are set, from which the integrated processor selects acharacteristic curve.

Parameter Material Parameter Gas

Steel CO2

Aluminium/Silicon 82% Ar, 18% CO2

Aluminium/Magnesium 90% Ar, 5% CO2, 5%O2

Chrome/Nickel 98% Ar, 2% O2

Programming according Pure Argonto customer requirements

Selector key Material Selector key Gas

Parameter Wire Operation mode

Wire diameter 0,8 (0.030) Normal 2 buttons

Wire diameter 1,0 (0.039) Normal synergic

Wire diameter 1,2 (0.045) Pulsed synergic

Wire diameter 1,6 (1/16) TIG (DC) "ScratchStart"

Programming according Electrodeto customer requirements

Selector key Wire Selector key Mode

More details on the operation modes and procedures are in the sections Welding andDefinition.


B-8


B1.2 Operating elements on the wire drive unit

Switch Pulse adaptationor choke

Push button Switch With/Wire manual without pulse

Push button Potentiometer 2Gas manual Arc length/

(Weld voltage)

Potentiometer 1Output (wire feed)

During pulse operation the switch 'Pulse adaptation or choke' enables an adaptation ofpulse energy, sometimes required for different cable assembly lengths.During normal operation this switch 'Pulse adaptation or choke' is used to set the chokeinfluence.

The table below shows the function of the two Potentiometers, depending on the selectedProcedure.

Procedure Normal Normal Pulse TIG Electrode2 buttons Synergic Synergic

Poti. 1 Wire feed Output Output Current Current

Poti. 2 Weld voltage Arc length Arc length no function

The Switch without/with pulse is active if the procedure Normal-Synergic or Pulse-Synergic was selected. You can change over from characteristic curve Normal synergic toPulse synergic.

B1.2 Operating elements Wire drive unit

B-9

OperationGLC 353/503 MC3

B1.3 Working modesDisplay 3 indicates the active mode of the weld power source control.There are two modes:

- Mode Manual

- Mode Programming

Mode Manual:

If two minus characters are shown on display 3, you canselect all values on the power source operation paneland start welding. On the wire drive unit operation panelthe arc condition is set via potentiometers 1 and 2.Welding in this mode is described in chapter B2 welding.

Programming Mode:

If a figure between 1 and 50 is shown on display 3, a storedweld process job is called up.In this case welding is carried out with programmedvalues.

B1.3 Arbeitsmodis

B-10


B-11

WeldingGLC 353/503/553 MC3

B2 Welding

B2 WeldingHereafter please find the operating instructions for the five welding processes.Please note the following three important instructions:

Operation of selector keys:

Example: You want to select the operation mode. The basic setting is"operation mode 4 cycle" which is indicated by theLED. By momentarily pressing theselector key operation mode the next operation mode is switched on etc.If the last operation mode is indicated and the key is pressed again, thedisplay jumps back to the first operation mode.

Flashing of LEDs:

The LEDs flash up in accordance with the combination ofselected values on the operation panel characteristic curveselection.This flashing signals that there is no characteristic curveavailable for this setting. In our example, the values

Steel

and

Argon

have been set. There is no characteristic curve for acombination of these values because welding is not possiblewith this setting.

Select mode manual:

For the following explanations it is required to set the powersource to mode manual.

Please proceed as follows:

When a number appears on display panel 3, press the keyDown until two Minus signs light up.Mode manual is switched on now.

B-12

Welding GLC 353/503/553 MC3

B2.1 MIG-MAG Normal 2 knob

B2.1 Procedure: MIG-MAG Normal 2 knob operationThe following instructions inform you how to use the power source with 2 knob operation,without internal characteristic curve.The welder determines the characteristic curve and the working point on the characteristiccurve with the values wire feed speed and weld voltage. After setting the processvalues atthe power source operation panel, the values wire feed and weld voltage are selected atthe wire drive unit operation panel.


- Switch machine on

- Select the Operating mode by pressing the key.In our example the operation mode 2 cycle has been set.

- Set the Material to be welded:In our example Steel is used.

- The Gas used has to be set with the following key:

Mixed gas is used, consisting of 98% Argon and2% CO2 .

- Set the Wire diameter with the following key:

In the example 1,2 mm diameter welding wireis used.

- Select the Procedure by pressing the following key:When welding with 2 knob operation without pulse, the upperLED flashes (see photo).

- Set the Display 1by pressing the selectorkey until m/min for the wirefeed speed is highlighted.

After setting, the LEDs light up asshown on the photo.

B-13


- Select the required Wire feed speed by turningPotentiometer 1 on the wire drive unit operation panel.The set value is shown on Display 1 of the powersource.

- Begin welding.

Poti 1 Poti 2 Caution!Protect eyes and skin against arcradiation ! Wear protective clothing !

- Turn Potentiometer 2 to adapt the Weld Voltageto the set wire feed speed.

- Carry out test welds and optimize the settingson Potentiometer 1 and 2.

- The actual weld parameters voltage and currentare shown on Display 1 - position Volt and onDisplay 2 - position Ampere.

Note: If you select AHold on Display 2, the maximum welding current used duringwelding can be read at the end of the welding process.

B2.1 MIG-MAG Normal 2 knob

B-14


B2.2 MIG-MAG Normal Synergic

B2.2 Procedure: MIG-MAG Normal Synergic operationThe procedure Normal Synergic can also be designated as single knob operation withprecise setting. The power source processor provides a characteristic curve for anycombination of the values Material, Gas and Wire diameter. Set these values on the powersource operation panel. The characteristic curve working point is selected with thepotentiometer arc output. You are then able to carry out a precise setting with Arc lengthpotentiometer. The potentiometers are arranged on the operation panel of the wire driveunit.


- Switch machine on.

- Select Operating mode by pressing the key:In our example the operation mode 2 cycle has been selected.

- Set the Material to be welded:In our example Steel is used.

- The Gas used has to be set with the following key:

Mixed gas is used, consisting of 98% Argon and2% CO2 .

- Set the Wire diameter with the following key:

In the example wire with a diameter of 1,0 mm is used.

- Select the Procedure by pressing the following key:When welding with Normal Synergic, the second LEDfrom the top must light up (see photo).

- Set Display 1 by pressingthe selector key until m/minfor the wire drive speedappears and Display 2 untilASet for the current setvalue appears.


B-15


- Select the required Arc output by turningPotentiometer 1 on the wire drive operation panel.The resulting values for Wire feed speed andWelding current set value can be read onDisplay 1 and 2 on the power source.

- Begin welding.

Poti 1 Poti 2 Caution!Protect eyes and skin against arcradiation! Wear protective clothing !

- Turn Potentiometer 2 to adapt the Arc length tothe set arc output.

- Carry out test welds and optimize the settings onPotentiometer 1 and 2.

- The actual weld parameters voltage and current areshown on Display 1 - position Volt and on Display 2- position Ampere.

Note: Set Display 1 on position mm. The display shows a plate thickness which canbe welded with the set arc capacity. This is only an approximate value whichhas to be adapted during production !

If you select AHold on Display 2 the maximum welding current used duringwelding can be read at the end of the welding process.

B2.2 MIG-MAG Normal Synergic

B-16

Welding GLC 353/503/553 MC3B2.3 Procedure: MIG-MAG Pulse SynergicThe procedure Pulse Synergic can also be designated as single knob operation withprecise setting. The power source processor provides a characteristic curve for anycombination of the vaues Material, Gas and Wire diameter. Set these values on the powersource operation panel. The characteristic curve working point is selected with thepotentiometer arc output. You are then able to carry out a precise setting with the Arclength potentiometer. The potentiometers are arranged on the operation panel of the wiredrive unit.



- Select Operating mode by pressig the key:In our example the operation mode 4 cycle has been selected.

- Set the Material to be welded:In our example Aluminium/Silicon is used.

- The Gas used has to be set with the following key:Argon is used here.

- Set the Wire diameter with the following key.In the example the wire diameter used is 1,6 mm.

- Select the Procedure by pressing the following key:When weldig with Pulse Synergic, the third LEDfrom the top must light up (see photo).

- Set Display 1 by pressingthe selector key until m/minfor the wire drive speedappears and Display 2 untilASet for the current set valueappears.


B2.3 MIG-MAG Pulse Synergic

B-17


- Select the required Arc output by turningPotentiometer 1 on the wire drive operation panel.The resulting values for Wire feed speed andWelding current set value can be read onDisplay 1 and 2 on the power source.

- Begin welding.

Poti 1 Poti 2 Caution!Protect eyes and skin against arcradiation ! Wear protective clothing !

- Turn Potentiometer 2 to adapt the Arc length tothe set wire feed speed.

- Carry out test welds and optimize the settingsby turning Potentiometer 1 and 2.

- The actual weld parameters voltage and current areshown on Display 1 - position Volt and on Display 2- position Ampere.

Note: Set Display 1 on position mm. The display shows a plate thickness whichcan be welded with the set arc capacity. This is only an approximate valuewhich has to be adapted during production!

If you select AHold on Display 2 the maximum welding current used duringwelding can

be read at the end of the welding process.

B2.3 MIG-MAG Pulse Synergic

B-18

Welding GLC 353/503/553 MC3B2.4 Procedure: TIG Direct-CurrentFor TIG Direct-Current Welding you only have to select the operating mode and thewelding current. The arc is ignited by touching the workpiece with the Tungsten electrode.The Soft-Start function provides lower ignition current and prevents electrode damageduring this procedure. After arc ignition, the welder pulls the welding torch away from theworkpiece and the power source increases the welding current to the set value.



- Select the Operating mode by pressig the key:In our example the operation mode 4 cycle has been selected.

- Select the Procedure by pressing the following key:When welding with TIG Direct-Current, the forth LED fromthe top must light up (see photo).

For this welding procedure, it is not required to set the valuesMaterial and Wire diameter.The value Gas is automatically adopted to the gas type Argon.

- Set Display 2 by pressingthe selector key until ASetfor the current set valueappears.


B2.4 TIG Direct-Current

B-19


- Select the required Welding current by turningPotentiometer 1 on the wire drive operation panel.The set welding current can be read on Display 2on the power source.

- Begin welding.

Poti 1 Caution!Protect eyes and skin against arcradiation! Wear protective clothing !

- Carry out test welds and optimize the setting byturning Potentiometer 1.

- The actual weld parameters voltage and current areshown on Display 1 - position Volt -and on Display 2 - position Ampere.

Note: If you select AHold on Display 2 the maximum welding current used duringwelding can be read at the end of the welding process.

B2.4 TIG Direct-Current

B-20

Welding GLC 353/503/553 MC3B2.5 Procedure: Coated stick electrodesThe power source provides the operating mode Electrode for welding coated stickelectrodes.


- Switch machine on

- Select the Operating mode by pressing the following key:When welding with Electrode the lower LED flashes(see photo).

During this welding process it is not required to set the values Operating Mode,Material , Gas and Wire Diameter.

Caution!Open circuit voltage is available at the connection lugs P and N andat the stick electrode!

- Set Display 2 by pressingthe selector key until ASetappears for the current setvalue.


B2.5 Coated Stick Electrodes

B-21


- Select the required Welding current by turningPotentiometer 1 on the wire drive operation panel.The set welding current can be read on Display 2on the power source.

- Begin welding.

Poti 1 Caution!Protect eyes and skin against arcradiation! Wear protective clothing !

- Carry out test welds and optimize the setting byturning Potentiometer 1.

- The actual weld parameters voltage and current areshown on Display 1 - position Volt -and on Display 2 - position Ampere.

Note: If you select AHold on Display 2 the maximum welding current used duringwelding can be read at the end of the welding process.

B2.5 Coated Stick Electrodes

B-22


B-23

ProgrammingGLC 353/503/553 MC3

P Programming

The welding power source MC3 enables to program and save 50 jobs (weld programs). Thevalues to be programmed depend on the operating mode used.

Once the welding programs are saved, they can be called up using the job number.

The following values are saved

- Material- Wire diameter- Gas- Procedure- Wire feed speed or output- Weld voltage or arc length

P1 Operating elements for programming

Display 1 shows the actualvaue

Display 3 shows theworking step and theweld proceduresequence numbe

Display 2 shows the actualvalue

Operating modes canbe selected Key Up increases the

actual value

Key Increments of 10changes the keys Upand Down inincrements of 10

Key Down reduces theactual value

Key Save loads the set valueinto the memory

Graphic aid forprogramming

P1 Bedienelemente fr die Programmierung

B-24

Programming GLC 353/503/553 MC3

P2 Program steps

By means of the graphic aid all possible program steps are shown. The abbreviations for theprogram steps are shown on display 3. The abbreviations are explained below:

-G Gas preflow 1 Main parameter 1 E End crater programin Wire "inching-in" speed 2 Main parameter 2 b BurnbackS Start parameter 3 Main parameter 3 G- Gas postflowu Start ramp (Upslope) d End crater ramp

P3 Operating modes during programming

The number of program steps depends on the operating mode. Actuate the torch trigger tochange to the next program step. The following drawings explain the connection (association)between operating modes, possible program steps and welding torch trigger.

Operating mode: 2 and 4 cycle:

Program steps

4 cycle

2 cycle

Welding torch trigger

The diagram shows the connection between the program steps and the actuation of the torchtrigger as well as the difference between the operating modes 2 cycle and 4 cycle.

P2 Programmschritte

B-25

ProgrammingGLC 353/503/553 MC3Operating mode Super 4 cycle:

Program steps

Welding arc active

Squeeze trigger Release trigger Squeeze trigger Releasetrigger

Welding torch trigger engagement(s)

The program steps Start program with start ramp and End crater program with end craterramp distinguish the operating modes 2 cycle/4cycle and the operating modeSuper 4 cycle.

Operating mode Prog

Program steps

Welding arc active

Welding torch trigger

In operating mode Prog the program steps Main parameter 2 and Main parameter 3 arepossible. When touching the welding torch trigger you can select between 3 settings. Whenpressing the welding torch trigger for < 0,3 seconds only, you remain within the programsteps 1,2,3.This means if you are in program step 3 and press and release the torch trigger within 0.3secs, the power sources changes to program step 1. The program step End crater ramp isstarted only when pressing the trigger for a longer period.

P3 Betreibsarten beim Programmieren

B-26


P4 Programming a weld procedure sequence

The example shows how to program the power source. The number of program stepsdepends on the operating mode used (see P3 operating modes during programming).In our example the operating mode Prog has been selected where all program steps arepossible. If you decide for one of the other operating modes the relevant program stepscannot be carried out.

In some program steps welding is required to test and adapt the values !

Caution!Protect eyes and skin against arc radiation!Wear protective clothing !

Procedure:


- Select the required Operating mode . Actuate the key:In the example the operating mode Prog has been selected.

- The first setting to be made is the Material:In the example Steel has been selected.

- The Gas to be used is selected on the following key:

Mixed gas with the components 90 % Argon,5 % CO 2 and 5 % O 2 has been selected.

- For setting the Wire diameter use the key:In the example 1,2 mm wire has been selected.

- Select the Procedure by pressing the key:Set Pulsed Synergic .

- Press the key Down until the display shows twominus signs " - - ".

4

2

P4 Programmieren eines Schweiprozessablaufs

B-27


When all values have beenset, the operation panelshows the following:

- Turn Potentiometer 1 and 2 at theWire drive unit to mid-position.

- Press the key Operating mode formore than 1 second.

- The first program step to be made issetting of Gas preflow.

Actuate the keys Upor Down until the requiredvalue has been set.

- Press and release the key Operating mode .The next program stepWire Inching can be entered.


For robotic operation:The inching-in value is used asset value, if the command "Wireby hand" (currentless wireadvance) is given and an externalcontrol voltage is not available.

4

2

4

2


5

B-28

Programming GLC 353/503/553 MC3- Press and release the key Operating mode

to enter the value Start capacity.

You can now weld the sizes.

Use the keys Up orDown until the required archas been set. The potentiometerson the wire drive unit operationpanel can be used for aprecise setting.

- Press and release the key Operating mode .The Start ramp can be entered.


- Press and release the key Operating mode andenter the Main parameter 1 value.

You can start welding to test and adapt the values.

Use the key Up orDown until the required arc hasbeen set. The potentiometerson the wire drive unit operationpanel can be used for aprecise setting.

4

2

4

2

4

2


B-29


4

2

4

2

4

2


- Press and release the key Operating mode again.Main parameter 2 can be set.

Proceed in the same way as described forsetting the Capacity 1.

- After setting the Main parameter 2, press the keyOperating mode .You can now set Main parameter 3.

Please proceed in the same way as describedfor setting Main parameter 1 and 2.

If you want to weld with Main parameter 1 and 2 onlyyou just have to turn the wire feed ofMain parameter 3 to 0.

- Press and release the key Operating mode .Set the time for End crater ramp.


B-30


- The next value to be entered is theEnd crater parameter . Press the keyOperating mode and set the requiredcapacity.

Start welding to determine the requiredvalue.

Use the key Up orDown until the required archas been set. The potentiometerson the wire drive unit operationpanel can be used for precisesetting.

- Press and release the key Operating mode . Enterthe percentage for Wire burn back.

Use the key Up orDown until the required valuehas been set.

- The last value to be programmed is theGas postflow . Press and release the keyOperating mode .

Use the key Up orDown until the required valuehas been set.

4

2

4

2

4

2


B-31



Note: If you press and release the key Operating mode now, the display jumps backto the value Gas preflow and shows the programmed value. You can modify thevalues (using the keys Up and Down ) or jump to the next value by pressing theOperating mode.

- Press and release the key Save.

The display on Display panel 3 flashes.

Use the keys Up or Down toselect a number between 1 and50 (in the example 44) to savethe values which have beenprogrammed.

- Press and hold the keySave until the display stopsflashing.

You have programmed a weld proceduresequence under the number 44.

Note: If the values have been saved in mode Manual (two minus signs on display 3),the programmed values are called up when working without Weld proceduresequence.

B-32


P5 Calling up a weld procedure sequence

Actuate the key Up orDown until the number ofthe required weld proceduresequence appears on the display.

P6 Correct a weld procedure sequence

Call up a weld procedure sequence. For modifications press the key Operating modefor approx. 1 second. You may now modify the values as described in chapter P4Programming a weld procedure sequence.

P5/6 Aufruf & Korrigieren eines Schweiprozessablaufes

Configuration menu

From software V1.56 up it is possible to configure the MC3.

The configuration menu is called up by pressing the key "Wire diameter" for a long time. Theother parameters in the configuration manu are called up by briefly pressing this key.Use the "Save" key to quit the menu.The following configuration parameters are available.

From version V1.56 up LOC: ( Key switch function ) GAS: ( Gas flow sensor yes / no ) ADJ: ( Adjustment range )

Extension from version V1.58 up ROL: ( Diameter of rollers )

Extension from version V1.59 up DOC: ( Weld data documentation )

Extension from version V1.60 up F1: ( Torch function )

B-33

ProgrammingGLC 353/503/553 MC3Extension from version V1.62 up NR: ( Machine number )

Extension from version V1.63 up ( special customers' requirement ) /series from version V1.64 up F2: ( Control voltage control ) F3: ( Remote controller - configuration )

LOC:The first parameter to be configured is the function of the key operated switch. The abbreviationLOC is shown on the current display. The locking position can be set between 0 and 4 using thearrow keys.

LOC 0 : The storage of jobs is blocked, but all other functions are possible. Thiscorresponds to the former key switch function and is also used as defaut value.

LOC 1 : In addition to LOC 0 the programming function via operating mode selection key isalso blocked. Consequently, the other parameters such as gas preflow, inching-inetc. cannot be changed.

LOC 2 : In addition to LOC 1, the characteristic curves cannot be changed via the keysmaterial, gas, wire diameter and procedure. It is not possible to change over toother characteristic curves. It is still possible to change the jobs and to set theoperating mode.

The following LOC3 and LOC4 functions are available from software V1.61 up.

LOC 3: This setting allows a change-over from 2 cycle to 4 cycle function; all otherfunctions of the operation field are blocked.

LOC 4: The complete operation field is blocked with this adjustment.

The restrictions in the operating functions are correspondingly transferred to the remote controllerfunctions.

DOC:With this parameter it is possible to document all the relevant process data (seam number,job number, average current, etc.). However, an additional weld data documentation set isrequired for these records.This documentation must be switched off during PC operation !

ROL:Three wire drive units are available, which can be selected with this parameter using thearrow keys.1. 30 : (Standard drive, 2+2 rollers, 30mm)2. H40 : (HD drive, 2+2 rollers, 40mm)3. E40 : (HD drive, 2+2 rollers, 40mm, ELVI motor - special!)

GAS:With the parameter gas sensor, you can change over between "ON" and "OFF", using thearrow keys. When a gas sensor is available, "ON" must be set.

ADJ:This parameter enables an adjustment range to be set for each job. The range of values isbetween 0 and 100%. The arrow keys are used for setting, for increments of 10 also use the key+10.

B-34

Programming GLC 353/503/553 MC3In the case of locking via key-operated switch, the capacity (the wire feed speed) can be alteredwithin the set window.This window is calculated from the standard value of the job and the set percentage value. Thestandard value is defined by saving a job (on the power source or remote controller FB1 or FBB1).

Caling up a job on the power source always activates the standard values. If a job is called up viaFB1 or FBB1, the job with the latest setting is always activated.If the power source has not been locked via key-operated switch, each parameter can be alteredwithout restriction (not valid for key-operated torches!).

NR:With this parameter the machine numbers of the power sources can be configured.This is required if several power sources are connected to one network.It is important that all power sources connected have different machine numbers becauseotherwise the communication with a PC is not possible. The machine number is set with thearrow keys.

F1:When you select F1 (key-operated torch), the arrow keys are used to change over between"ON and "OFF". When a key-operated torch is connected, "ON" must be active.

During normal operation ( ), the plus/minus keys on the torch are used to alter the energy in thecomplete program range. The last welding value set is saved.The mid-position of the precise adjustment potentiometer has the value "0". The minimumvalue of this potentiometer is -128, the maximum value +128. When the preciseadjustment is altered, the set value (e.g. +50) is shown in the display panel 2 for approx. 3s.During job operation - e.g. job 01 - the plus/minus keys on the torch can be used to select anotherjob in the weld pause.During welding the same plus/minus keys on the torch can be used to alter the energy. Theadjustm ent range can be determ ined with the param eter ADJ. This requires the installation of akey-operated switch.The potentiometer "Power" is inactive in this operating mode.

F2:This paramter can be configured ON or OFF.The control voltages of both potentiometers P1 and P2 can be checked in the case of an "ON"configuration.The set control voltage for the capacity is shown on the display panel 1 of the power source.The set control voltae for the precise adjustment is shown on the display panel 2 of the powersource.The parameter automatically returns to "OFF" after each new start of the power source ( machineoff/on switch).

F3:This parameter can also be configured ON or OFF.OFF When the job is changed via remote controller FB1 or FBB1,

the modified values are maintened.ON When the job is changed via remote controller FB1 or FBB1,

the originally programmed value is used as setting.

B-35

Service and MaintenanceGLC 353/503/553 MC3

S FaultsFaults are divided into three categories:

- Problems during operation

- System fault Overtemperature

- Error messages

AttentionBefore any work is carried out inside the power source, the machinemust be switched off and the mains plug disconnected.

After disconnecting the mains plug, wait at least two minutes until thecapacitors in the intermediate circuit have reached safe values!

After maintenance and repair work the side panels and top cover have to be reinstalled.

S1 Problems during operation

Faults which occur when welding can be rectified by qualified personnel or the welder.Location of electrical faults of repairs must only be carried out by trained service personnel.

If a fault cannot be rectified by your own service staff, please contact your nearest officialCLOOS reresentative.A list of addresses of Cloos representatives is enclosed (see appendix).

Faults:

- Welding machine cannot be switched on:

1. Check the power lines.

2. Check the T2 transformer. Make sure that it is connected according to thecorrect mains voltage.

3. Check the fuses in the welding machine.


Service and Maintenance

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GLC 353/503/553 MC3

- No welding current or very little supplied by machine:

1. Loose contact or arcing at:- welding current connection lug (P)- welding current connection lug (N)- torch connection- central connection (wire drive unit)- earth connection- workpiece clamp (welding ground)

2. Fault in the welding machine

Wire drive unit does not work properly:

1. The wire feed parts (wire drive roller etc.) fitted are for the wrong diameter wire.

2. The wire is bent.

3. The surface is not clean.

4. Counter pressure roller is loose.

5. Wire coil brake is too tight.

6. Tolerance within wire drive is not correct.

Weld seams are porous:

1. Component severely rusted or contaminated by paint/oil or double plate.

2. Distance between welding torch and workpiece is too large.

3. Leaking gas supply.

4. Porosity caused by magnetic blowing action of the welding material. Aspreventive measure always keep welding movement away from the workpiececlamp.

5. Welding torch is held too flat.

6. Gas flow is set too high or too low.

7. Polluted or incorrect gas.

8. Cross wind blows away the shielding gas, i.e. due to open doors or fans.


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Service and MaintenanceGLC 353/503/553 MC3S2 System fault Overtemperature

The following components are provided with a temperature switch:

- Water cooling pump (motor winding)- Fan (motor winding)- Main transformer T1- Rectifier- Heat sink in cascade 1 1- Heat sink in cascade 2 (GLC 503/553 MC3 only)

In the case of overload, the corresponding temperature switch opens.The arc is switched off and the light diode Temp on the operation panelof the power source signals the fault.

Cause:

- Pump is overloaded by contaminated cooling agent or blockedhoses.

- Motor is faulty.- Permissible duty cycle has been exceeded.- The cooling air inlet and outlet are covered or contaminated.- The welding machine interior is severely contaminated.- The ambient temperature is more than 40 Celsius.

When a flow switch for water cooling (optional) is installed, the LED Temp flashes in the caseof no or unsufficient cooling water flow.

S3 Error messages

CS Test number error

When the message 'CS' appears on display panel 3, this indicates an error in the data memoryof the machine. The PC Software MC3 is required for correction of same. You will find moredetails in the PC Software Manual under Diagnosis/Memory administration and Backup.

S2 System fault Overtemperature


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GLC 353/503/553 MC3

W Maintenance

W1 Information, intervals

Regular maintenance of the machine is essential for safe and troublefree operation. Thenecessary maintenance work and repair work must therefore be carried out at regularintervals.This is in any case required by the safety regulations !

The maintenance of the machine mainly concerns the welding torch. The life of the gasnozzles and current tips, which are subject to wear, can be extended considerably if theyare sprayed from time to time with torch spray, which allows easier removal of weld spatteror prevents their adhesion altogether.The liners must be cleaned after welding 50 - 100 kgs wire, depending on wire size. To dothis they are pulled out of the outer hose. The outer hose and the liners are blown out withdry and clean compressed air.

Attention!Before any work is carried out inside the power source, the machine mustbe switched off and the mains plug disconnected.

After disconnecting the mains plug, wait at least two minutes until thecapacitors have reached safe values!

Daily checks

1. Please check the machine for abnormal vibration, humming noise and smell.

2. Please check the connection lugs, cables, hoses and torch for abnormal heating,insulation faults, leaks and cleanliness!

3. Please check the coolant level in the container.

4. Please check the wire drive unit. Welding wire abrasion must be removed by usingdry compressed air, which also prevents premature wear.The mechanical drive parts must be cleaned and greased at regular intervals.Do not lubricate the drive rolls; this would cause the wire to slip !

5. Attention! If a filter is mounted at the front of the air entry, it must be cleaned whendirt collects on its surface. Otherwise the duty cycle of the machine is reduced andthe temperature of the torch coolant is increased to an inadmissible range.Please use caution!

W1 Maintenance: Information, Intervals

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Service and MaintenanceGLC 353/503/553 MC3Monthly checks1. Please check the cooling fluid for cleanliness.2. Please check the cooling radiator at the rear of the machine for cleanliness.

Quarterly checksThe water cooling pump is provided with a filter which must be checked and, if necessary, cleanedafter 250 working hours. To do this, the welding machine must be switched off and opened andthe filteron the pump removed. The filter is located at the bottom of the pump body below a capnut. It should be cleaned using running water, otherwise the welding torch may be damaged dueto overheating !

Bi-annual checks1. Please check the interior of the machine and the components for dust and dirt.2. Please check the mains cable and welding cable for a firm seat and good contact.3. Please ensure that the machine is always correctly connected to earth (grounded).4. Please check that the machine cover is correctly assembled and fits tightly.5. Please check the cooling radiator for bent laminas and re-aligh, if necessary.

W2 Special instructionsW2.1 Dust and dirt

W2.1.1 The cooling efficiency of the radiator, item 88 at the rear, largely depends onthe cleanliness of the laminas. These have to be cleaned at regular intervals.It is recommended that cleaning is carried out by blowing dry, oil-freecompressed air through the radiator. This will remove any dust and the radiatorwill regain its original cooling efficiency.

W2.1.2 Dust and dirt on the main transformer, rectifier, etc. affect the cooling efficiencyof the fan. Metal dust on the main transformer may also lead to insulationproblems and cause earth or winding short circuits. Depending on the degree ofcontamination these parts must be vacuum cleaned, .We advise you not to use compressed air because this would increase the dustpenetration into the components!A vacuum cleaner can also be used to clean the upper wiring area. As this areais sealed, this work is only required at relatively long intervals.

W2.2 Cooling agent, anti-freeze agent, disposal

The coolant must be drained off if it is contaminated (it usually becomes a brownish color).When it must be disposed of , in accordance to State or local codes.

- It must not enter the main drainage system. -

W2 Special instructions


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GLC 353/503/553 MC3

The complete cooling system must then be rinsed with fresh distilled water, re- filling,circulation with the aid of a pump, draining off as far as possible; if necessary usecompressed air. The new cooling agent can be refilled as described under III. in theoperating instruction manual, paragraph 8: Cooling agent.

Only use

CLOOS cooling agent - Part No. 000 01 01 31

which contains

anti-freeze up to -200C

and also protects against corrosion .

Clean cooling agent prevents erosion of the torch body and other parts ofthe cooling water system due to electrolytic effect !

W2 Special instructions

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OptionsGLC 353/503/553 MC3

O OptionsThe power source GLC 353/503/553 MC3 can be equipped with the following options:

- Key-operated switch

- Serial interface

- Remote controller - connected at CK 98 A -

- Automation interface

These options are described below.

O1 Key-operated switchThe installation of a key-operated switch enables to protect the memory contents ofwelding procedures against modifications.This means : It is impossible to save modifications.

O2 Serial interfaceThe serial interface enables to connect the power source to a PC or laptop, where thePC-Software MC3 program developed by Cloos is installed. This option enables thefollowing functions:

- Save characteristic curves and welding processes in the PC

- Transmit characteristic curves and welding processes to the power source

- Generate characteristic curves

- Print characteristic curve data

O1 Key-operated switch O2 serial interface

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Options GLC 353/503/553 MC3O3 Remote controller

Remote controller connection

The remote controller enables you to changevalues when welding takes place far away fromthe wire drive unit. The remote controller isconnected at the wire drive operation panel. Thepotentiometers 1 and 2 on the wire driveoperation panel are switched off as soon as theremote controller has been plugged in.

Remote controller operation panel:

Call up the welding processes 1 to 7.

Change over from mode manual tomode programming.

Potentiometer 2.1: Welding voltageArc length

Potentiometer 1.1: Wire feed speedoutput

O3 Remote controller

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OptionsGLC 353/503/553 MC3O4 Automation interfaceAn automation interface is used if a coupling between the power source and external controls(i.e. PLC control) is required. The following external signals can be received via automationinterface:

- Selection of a welding process

- analogue inputs for control of wire feed speed/capacity and voltage/arc length

- digital input for continuation of capacity 1, 2, 3 in operation mode Prog

- digital input for external Start and external Gas

The signals

- arc present

- collective fault

will be sent to external controls.

Accessories coding according to the following list is required!

Resistance values for coding of accessories (remote controller etc) to GLC 353/503/553 MC3.For coding accessories to the power source a resistor must be instelled between +10V and theinputs X7/C4 (remote controller socket on wire drive unit) or X15/B7 (peripheral socket).In the case of the MC3/R a bridge is required beween X15/28 and X15/31.It is recommended that the resistor is installed in the plug of the remote controller or theconnection cable of a higher voltage control so that the coding is only applicable if the relevantunit is connected to the power source.

CAUTION ! If a remote controller and a higher voltage control (e.g. a robot) are simultaneouslyconnected, coding is only allowed on one of the two plugs.

Coding is carried out in steps of 1 Volt, the resistor to be installed represents the upper arm ofa voltage divider. The lower voltage divider is already provided in the control.The following resistance values are used to set the corresponding voltage level:

8,2 k Ohm 1V Remote controller 038 05 01 00 connected to CK3,6 k Ohm 2V2,2 k Ohm 3V1,3 k Ohm 4V910 Ohm 5V 1.) Change-over to external set values (control voltage 5+6

above X15)2.) ST 104 MC3:

The 2nd torch trigger is only used for change-over to CK 2;welding on with external start.

620 Ohm 6V ST 104 MC3:The 2nd torch trigger is only used for change-over to CK2;welding on with external start.

390 Ohm *7V 1.) Change-over to external set values (control voltage 5+6above X15)

2.) Wire currentless with torch trigger220 Ohm 8V100 Ohm *9V Wire currentless with torch trigger0 Ohm 10V Robot version* Version 1.50 and higher

O4 Automation interface

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Options GLC 353/503/553 MC3Accessories coding forGLC 353/553 MC3, MC3/R

Set values Set values External Wire current- Robot CK change-overof CK external start less from torch version external

8,2 k 1V x - x - - -3,6 k 2V2,2 k 3V1,3 k 4V910 5V - x x - - x620 6V x - x - - x390 *7V - x x x - -220 8V100 *9V x - x x - -0 10V - x x x x x

* Version 1.50 and higher

Resistor or bridge in

GLC...MC3Automation socket X15between A1 (+10V) and B7 (accessories coding)

GLC...MC3/RPeripheral socket X15between 31 (+10V) and 28 (accessories coding)

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Elektr. und mech. Beschreibung / electr. and mech.description / description mc. et lectr. GLC 353/503/553 MC3

Ersatzteillisten

Spare parts lists

Listes des pices de rechange

L-2

Elektr. und mech. Beschreibung / electr. and mech.description / description mc. et lectr. GLC 353/503/553 MC3

7. Abbildungen Schweigert

350mc3_e

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