MEK 4S
Contents
1. fig 2 ja sen on taivuttava kuva 2 A WARNING There is a risk of tipping if the wire feed cabinet is fitted with a counterbalance arm Secure the equipment especially if used on an uneven or sloping surface Limit the angle of rotation of the wire feed cabinet using the straps supplied When moving the equipment do NOT pull on the torch 39 bm24e 6 1 Starting to weld By moving the plug 17 to the upper or lower position you can switch between two different start modes Normal start with the plug 17 in the lower position the wire feed speed at the start of welding is the same as the preset wire feed speed during welding Inch start with the plug 17 in the upper position the wire feed speed at the start of welding is reduced 1 9 m min and then rises to the preset wire feed speed when the arc is established 6 1 1 Synergic mode Set the toggle switch on the circuit board 25 to position A and set the selector switch on the front panel 22 to the synergic line that matches the wire type wire diameter and gas you intend to use There are 8 synergic lines to choose from see table page 44 When the Pre set button 23 is pushed in the wire feed speed and voltage are shown on the display The green lamp 24 above the voltage control will light up when the voltage falls on the synergic line You can use the voltage control knob 8 to adjust the voltage around the working point The actual volta2. welding parameters you have selected press the save button 20 until the green lamp 21 lights up You can save three different working settings using the program selector switch 6 4 Program mode To use one of the 3 stored working settings switch the function selector switch 22 on the front panel to mode P and the program selector switch 19 to mode 1 2 or 3 to recall the chosen data and begin welding These weld data settings can also be recalled using the program selector switch on the welding torch It is not possible to adjust the voltage or the wire feed speed around the chosen working setting 41 bm24e 7 MAINTENANCE Note All warranty undertakings given by the supplier cease to apply if the customer attempts to rectify any faults on the machine during the warranty period Regular maintenance is important for safe and reliable operation e Regularly blow the wire liner clean and clean the gas nozzle The wear components of the wire feed mechanism should be replaced at regular intervals in order to ensure reliable wire feeding Note that using excessive pressure on the wire feed rollers can cause excessive wear to the pressure roller feed roller and wire liner The brake hub The hub is adjusted when delivered if readjustment is required follow the instructions below Adjust the brake hub so that wire is slightly slack when w
3. A NNN BIREN EN EEN cee RN EEN EIS 64440664 Cee a ews 37 5 INSTALLATION 52 62 24 38624 08438 2 00 a iin Let eee 37 et SGONNSCI N iz serrate tees puna E rr Ei ees 38 6 OPERATION sta eege 39 6 17 Starting to Weld psa fria h RR pi tac pad iia ts 40 6 2 Manualimod eu ZENNER TER O De ree RER TRR ee 41 6 3 Saving the working Setting 41 6 4 Program Mode cect a detract hee e ER PA CR FRS eet RA b RA 41 7 MAINTENANCE da 42 8 ORDERING SPARE PARTS c eee bee ees 42 DIAGRAM iia iaa Shee pecan a cates hee ad eek es 116 SPARE PARTS LIST soe lt lt SNE NK RENE RUE NEUENS NNN EEN SEN 117 ACCESSORIES EE 124 TOCe 35 1 DIRECTIVE DECLARATION OF CONFORMITY Esab Welding Equipment AB S 695 81 Lax Sweden gives its unreserved guaran tee that Wire feed unit MEK 4S from serial number 818 complies with standard EN 60974 1 in accordance with the requirements of directive 73 23 EEA and adden dum 93 68 EEA and standard EN 50199 in accordance with the requirements of directive 89 336 EEA and addendum 93 68 EEA Laxa 98 02 10 OE Paul Karlsson Managing Director Esab Welding Equipment AB 695 81 LAXA SWEDEN Tel 46 584 81000 Fax 46 584 12336 2 SAFETY A WARNING A ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS TAKE PRECAU TIONS WHEN WELDING ASK FOR YOUR EMPLOYER S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA E
4. LECTRIC SHOCK Can kill Install and earth the welding unit in accordance with applicable standards e Do not touch live electrical parts or electrodes with bare skin wet gloves or wet clothing Insulate yourself from earth and the workpiece e Ensure your working stance is safe FUMES AND GASES Can be dangerous to health e 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 e Protect your eyes and body Use the correct welding screen and filter lens and wear protective clothing Protect bystanders with suitable screens or curtains FIRE HAZARD e Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby NOISE Excessive noise can damage hearing Protect your ears Use earmuffs or other hearing protection e Warn bystanders of the risk MALFUNCTION Call for expert assistance in the event of malfunction READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING PROTECT YOURSELF AND OTHERS 36 bm24e 3 INTRODUCTION MEK 4S Synergic is an enclosed wire feed unit with four drive rollers Inside the wire feed unit there is space for a 300 mm diameter wire reel The unit also has a built in swivel mounting so that the wire feed unit can be conveniently mounted on top of the welding power source MEK 4
5. MEK 4S Bruksanvisning Brugsanvisning Bruksanvisning Kayttoohjeet Instruction manual Betriebsanweisung Manuel d instructions 0455 513 001 020924 Gebruiksaanwijzing Instrucciones de uso Istruzioni per l uso Manual de instru es Odnyleg xp oewa Instrukcja obstugi Valid for serial no 912 xxx xxxx STI 52 NEDERLANDS 0 0024444 61 ESPANOL e ee dete oat tect 70 ITALIANO asnos ciel E decides 79 PORTUGU S sE S 88 ENANA i cles Aue fie ccd ida ter diaria leia 97 POLSK EE EE EE 106 Ratt till Andring av specifikationer utan avisering f rbeh lles Ret til ndring af specifikationer uden varsel forbeholdes Rett til endre spesifikasjoner uten varsel forbeholdes Oikeudet muutoksiin pid tet n Rights reserved to alter specifications without notice Anderungen vorbehalten Sous r serve de modifications sans avis pr alable Recht op wijzigingen zonder voorafgaande mededeling voorbehouden Reservado el derecho de cambiar las especificaciones sin previo aviso Ci riserviamo il diritto di variare le specifiche senza preavviso Reservamo nos o direito de alterar as especifica es sem aviso pr vio Atatnpeitai To Sika Wua Tportonoinons Mpodiaypapwv Xwpic nposidonoinon Zastrzegamy sobie prawo do wprowadzenia zmian DIRECTIVE Sois a nla 36 2 SAFETY ivejncoricaiii EE 36 3 INTRODUCTION eos oes ria a en eee as 37 3 1 Explanation of synergic lines 37 4 TECHNICAL DAT
6. S has many features that welders will find very useful such as the ability to save settings for 3 different welding jobs and recall them later when needed You can read about this and much more on the following pages Details of ESAB s accessories for the wire feed units can be found on page 124 3 1 Explanation of synergic lines Each combination of wire type wire diameter and gas mixture requires its own unigue relationship between the wire feed speed and voltage arc length in order to maintain a stable and effective arc MEK 4S has 14 different combinations of pre programmed synergic lines Once you have chosen the pre programmed synergic line that matches your wire feed speed for your welding task The voltage arc length is automatically adjusted in accordance with the pre programmed synergic line you have chosen i e you have one knob control Because different welding tasks and joint preparations require slightly different voltages arc lengths the voltage can naturally be fine tuned either side of the pre programmed value When this is done the green light on the front panel goes out This indicates that the voltage is above or below the pre programmed value If you want to return to the original setting you simply adjust the voltage until the green light comes on again 4 TECHNICAL DATA Dimensions Ixbxh 606x240x410 mm Weight 14 kg Wire feed speed 1 9 25 m min Voltage 42 V 50 60 Hz Power demand 300 VA Torch co
7. ge and current are shown on the display during welding A further 6 synergic lines can be accessed by setting the toggle switch on the circuit board to gt B see table page 44 Fe 1 0 Ar 80 CO Ar 80 CO 20 Fe 1 2 Ar 80 CO Ar 80 CO 20 Ss 1 0 Ar 98 CO Ar 80 CO 20 Ss 1 2 Ar 98 CO Ar 80 CO 20 Al Mg 1 2 Ar 100 Ar 80 CO 20 Al Mg 1 6 Ar 100 s Ar 80 CO 20 Al Si 1 2 Ar 100 Al Si 1 6 Ar 100 PAH1 D gt 6 1 2 Creating your own synergic lines If the pre programmed synergic lines do not suit your combination of wire wire diameter and gas maxture you can use the PAH1 controller part no 0455 525 880 to create 2 synergic lines of your own and save them in the MEK4S menory See the user manual for the PAH1 controller Contact your nearest ESAB dealer for more information about this feature 40 bm24e 6 2 Manual mode Adjusting voltage and wire feed speed Set the selector switch on the front panel 22 to manual Hold in the pre set button 23 while you set the desired voltage and wire feed speed on the display The actual voltage and current are shown on the display during welding NOTE Pulse welding is not possible in manual mode 6 3 Saving the working setting Set the program selector switch 19 to one of the three settings 1 2 or 3 Hold in the pre set button 23 while you set the desired voltage and wire feed speed on the display To save the
8. ire feed stops Adjusting the braking torque e Turn the red handle to the locked position e Insert a screwdriver into the springs in the hub Turn the springs clockwise to reduce the braking torque Turn the springs anticlockwise to increase the braking torque NB Turn both springs through the same amount 8 ORDERING SPARE PARTS Spare parts are ordered through your nearest ESAB representative see back cover When ordering spare parts please state machine type and number as well as desig nation and spare part number as shown in the spare parts list This will simplify dispatch and ensure you get the right part 42 bm24e
9. nnection EURO 5 INSTALLATION The installation must be executed by a professional A WARNING 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 37 bm24e O OO Y Oo Oo 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 bm24e Connection Nipples for connecting cooling wate Nipple for gas connection Connector for connecting control cable from power supply Adapter welding current from power supply Switch crater fill on off Digital meter Encoder wire feed speed 1 9 25 metres per minute Encoder welding voltage 14 Connector remote control Remote control is 15 activated automatically when connected 16 Nipples cooling water to from welding torch 19 Bracket for securing strap The securing 21 strap must always be used to secure 20 the wire feed unit to the power source during transport Hole for installing connector for PKE welding torch with built in feed motor Connector for welding torch Switch trigger latch on off Potentiometer burn back time 0 0 5 seconds Potentiometer crater fill ime 0 5 1 seconds Jumper inch start on off The jumper is fitted to connector B on the circuit board A Inch start on wire feed starts at 1 9 m min and then rises to set value Quick sta
10. rt for restarting with trigger latch on within a second of stopping welding Quick start takes place at set wire feed speed B Normal start wire feed starts at set value Brake hub Hub is pre adjusted prior to delivery Switch for program selection Pushbutton for storing settings Indicator lamp for stored settings Switch for function selection Pushbutton for pre setting wire feed speed and reference voltage Indicator lamp for working point Switch for selecting synergic lines 1A 8A or 1B 8B 38 6 OPERATION General safety regulations for the handling of the equipment can be found on page 36 Read through before you start using the equipment WARNING HA Rotating parts can cause injury take great care A WARNING To prevent the reel sliding off the hub Lock the reel in place by turning the red knob as shown on the warning label attached next to the hub Setting the wire feed pressure Start by making sure that the wire moves smoothly through the wire guide Then set the pressure of the wire feeder s pressure rollers It is important that the pressure is not too great cmek0p10 Fig 1 To check that the feed pressure is set correctly you can feed out the wire against an isolated object e g a piece of wood When you hold the pistol approx 5 mm from the piece of wood fig 1 the feed rollers should slip If you hold the pistol approx 50 mm from the piece of wood the wire should be feed out and bend
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