The Book of Welding
For the workshop and building site 2006 and 2007
2 / 1 . 0 0 0 1 . 3 1 9
Lorch Schweisstechnik GmbH D-71547 Auenwald Postfac h 1160 T. +49 (0)7191.503.0 (0)7191.503.199
[email protected] www.lorch.biz
F. +49
You are holding the book of welding
Presented by your dealer
You are holding the book of welding
Presented by your dealer
You are holding the book of welding
Presented by your dealer
Electrode welding CL Page 30
Electrode welding TIG welding H Page 10 ISI5 CL Page 28
TIG welding HT HandyTig
Page 17 Page 20
MIG-MAG welding A Page 34 M 2000 Page 44 M 3000 Page 48
MIG brazing A CuSi M 3030
Page 34 Page 55
Plasma cutting Z Page 64
Helmets/accessories Page 68
Data
Page 72
Our day-to-day work is all about putting the best possible instrument in your hands. As you see, we share a joint ambition: Top quality workmanship
6
Full 3-year warranty Which adds up to 8,760 working hours. 365 days a year - times three. This is the period for which we guarantee the functional characteristics of our products. We are confident that nothing can go wrong with a system or a unit bearing the name Lorch. But in the unlikely event that a fault should occur, we undertake to repair it and to shoulder the cost. As you will appreciate, this does not apply to wearing parts. 3 times longer than the statutory requirement. The law currently requires a fixed warranty on material and production defects in commercially used products of 1 year. Given our outlook on quality, for us this stipulation goes without saying. Subject to correct treatment in line with the operating instructions provided, we will grant you not just 1 year’s warranty from the date of purchase, but another 2 years on top. But please do tell us where your equipment is being used and who you are. Please return the warranty card ... ... to Lorch, Postfach 1160, D-71547 Auenwald. Otherwise we will NOT be able to fulfil our three-year warranty pledge. The warranty card is enclosed with your unit. You can also register online on www.garantie.lorch.biz. As soon as you have registered, you will receive your binding warranty certificate guaranteeing three years of cover from the date of purchase.
7
Process k MIG-MAG welding
Electrode welding Stick electrode
MIG brazing
Shielding gas nozzle
Shielding gas nozzle
Contact tip
Contact tip
Core wire
Electrode
Soldering electrode
Gas/Slag
Shielding gas
Shielding gas
Arc
Arc
Arc
Melt zone
Melt zone
Soldering material
Base material
Base material
Coating
Base material
Basic knowledge: Electrode welding
Basic knowledge: MIG-MAG welding
Basic knowledge: MIG brazing
The electric arc burns between the material
With the MIG-MAG method (MIG = Metal
Called MSG (Metal Shielding Gas) brazing
and melting electrode. The electrode simulta- Inert Gas/MAG = Metal Active Gas) the elec-
according to international standards - is a
neously supplies the filler metal. The stick
tric arc burns between the melting, automat-
hard-soldering procedure. The electrical arc
electrode is clamped in an electrode holder
ically supplied welding rod (= electrode) and
burns between the melting, continuously
and positioned by the welder. Stick elec-
the material. A separately supplied gas pro-
applied brazing wire electrode and the work-
trodes are generally coated. The coating also
tects the arc and welding zone against out-
piece. The added shielding gas protects the
melts and protects the molten pool and arc
side air. The shielding gas and welding rod
arc and the liquid brazing metal against the
against outside air by releasing gases and
must be matched to the base material.
influences of the ambient air. The applica-
slag.
Weldable materials include:
tion is as simple as MIG-MAG welding. MIG
The slag is removed after the molten pool
Aluminium, aluminium alloys
brazing offers clear advantages for the join-
cools.
Method: MIG
ing of galvanised sheets compared to MIG-
Devices marked with an (S) can also be used
Wire electrode: matched to the material to be MAG welding. Only a fractional zinc melting
under higher electrical risks. Inverter
welded
loss occurs in the immediate brazing zone
welders have very good welding properties
Welding shielding gas: Ar, He or mixtures
(zinc melts at 419°C, evaporates at 906°C)
and are thus also suitable for special elec-
General structural, boiler, tubular steel
due to the low melting temperatures of the
trodes. Nearly all weldable materials can be
Method: MAG
brazing wire ( approximately 1000°C). The
welded with stick electrodes, e.g. structural
Wire electrode: SG 1-3
soldering seam features a high corrosion
steel, boiler steel, steel tubes, cast steel,
Shielding gas: mixed gas (Ar/CO 2) or CO2
resistance and enables easier surface treat-
stainless steel, hard facing steels, etc.
Stainless steel, high alloy steel
ment. The soldering wires consist of copper
Electrode welding is simple and safe. The
Method: MAG
based alloy with a component of, for exam-
compact devices are easy to handle and
Wire electrode: matched to the material to be ple, silicon or aluminium. There is minimal
transport. Since no gas is needed, welding
welded
distortion, even on very thin sheets, due to
can be performed outdoors, even in wind.
Shielding gas: Mixed gases (e.g. Ar/CO 2 or
the low heat input. Coated (galvanised, phos-
Electrode weld machines are used in all
phated, aluminised) and uncoated steel
lines of business, from industry through to
Ar/CO2 /O2) MIG/MAG welding is the most popular weld-
craftsmen.
ing method nowadays on account of its enor-
steel compounds (black/white compounds)
mous advantages. The high welding speed,
may be soldered. Soldering seams provide
minimum reworking and low distortion
excellent assembly strength. Shielding gas:
ensure high efficiency. The great weld seam
pure argon or argon with minor additives.
strength, excellent thin-sheet properties and
Galvanised thin sheet is used in the automo-
simple and safe handling with steel, alumini-
tive engineering and building industries, in
um and stainless steel make the method uni-
air conditioning technology, household appli-
versally acceptable.
ances and in the furniture industry. MIG
sheets, stainless steel and steel/stainless
brazing is ideal for these applications.
8
owledge TIG welding
Plasma
Einstein
Gas nozzle Tungsten electrode Shielding gas
Arc
Electrode Cutting gas Cooling gas Plasma nozzle
Melt zone
Plasma arc
Base material
Base material
Basic knowledge: TIG welding
Basic knowledge: Plasma cutting
Basic knowledge: E = mc 2
With the TIG method (TIG = Tungsten Inert
When plasma cutting, the electrical arc
.....................................................................
Gas) the electric arc burns between the non-
burns between the non-melting electrode
.....................................................................
melting tungsten electrode and the workpiece.
and workpiece. The arc is additionally con-
.....................................................................
The arc is very intense and can be very easily
stricted by a nozzle and applied compressed
.....................................................................
controlled. A separately supplied argon shield-
air, which increases the intensity and stabili-
.....................................................................
ing gas protects the arc and the welding zone
ty considerably. Due to this constriction a
.....................................................................
from the atmosphere. Filler metals can be fed
highly heated gas with high energy content
.....................................................................
by hand or with a special cold wire feed if
originates in the torch, whose electrical ener-
.....................................................................
necessary. Steel, stainless steel, copper, titani-
gy is converted into heat. This ionised gas
.....................................................................
um, etc. are welded with direct current. The
which transfuses the arc onto the workpiece
.....................................................................
electrode is connected to the negative pole
is called plasma.
and ground to a point.
Cuttable materials:
Aluminium, magnesium and their alloys
By using the plasma-cutting procedure mate-
should only be welded with alternating cur-
rials such as steel, stainless steel, alumini-
rent to break open their oxide skin. The elec-
um, copper, cast, brass, etc. can be cut.
trode is blunt.
The special advantages:
During welding it can assume a round or
Due to the energy density of the plasma arc
crowned shape. With modern inverter power
a high cutting speed is obtained. The cuts
sources, a pointed tungsten electrode can also
are steep, flash- and distortion free and of
be used. The advantages of TIG welding: its
high economic eff iciency.
easy handling and good control over the arc
Trouble-free handling and use of simple com-
enable very comfortable and clean working.
pressed air as a cutting gas offer unlimited
The low oxidisation of the workpiece, small
possibilities. Used in the steel industry,
welding zone, omission of fluxing agents and
installation, container construction and
non-spattering arc ensure clean, precise
many other areas.
seams with no slag inclusions and no reworking.
9
We present: the better inverter. Drop it? Yes you can. Standards specify that an inverter welding device must be capable of withstanding a free drop of 25 cm. But let’s be honest: If a unit falls off a table or out of your hand it will be travelling a good 80 cm before it hits the ground. An H from Lorch is capable of surviving this degree of drop and will still go on working as reliably as ever. We don’t know of any other product which can make a similar claim. Statistics show that a unit is bound to be dropped 4 times over its useful life. So your choice of product is already looking a little clearer. Otherwise what’s to stop that clumsy apprentice sneaking a damaged unit back on the shelf and you shouldering the blame? Inside coating. This special coating of the electronic circuitry helps protect the inner workings of the inverter against failure due to high or low temperatures, dust, chips and moisture. Consistent HighTec An inverter’s job is to chop the current it takes from the mains. 100,000 times per second. Power off, power on. And if a part gets out of step by just 100,000th of a second (which is one switching cycle), you are on course for trouble. Digital current controller It takes a perfect microprocessor to regulate the arc correctly. All the better - and all the finer and more controlled the droplet transfer and the spatter formation. Its adaptive behaviour compensates for handling errors and helps stabilise the welding result. Even with difficult electrodes and in awkward confined spaces. It is a Bestseller or a Flop.
Do please measure the duty cycle at 40°C The dutycycle (DC) is the measurement variable which determines the loading capacity of a welding unit. In reality, many suppliers are willing to deceive their customers with exaggerated data - or theysimply quote the value at just 20°C. Energy-saving inverter technology Minimal power loss - high efficiency. Standby function for minimal energy consumption during breaks. Overvoltage and undervoltage protection Safeguards the unit against damage or defects caused by mains fluctuations within a broad tolerance range. Featuring generous extension cables for convenient use on site. Thermocontrol sensors Reduce the ingress of dirt bycontrolling the fan only as and when required. 10
The H C RAS H P ROO F
T ES T
W i n ne r A Lo rc h Ha nd y
H 1 5 0
e ig h t o f 80 c m. y d ro p f ro m a h w i ll s u r v i ve a n good we ld i ng p ro pe r t ies. 0 % DC. E x t re me l y i ng c u r re n t, 10 Ma x i m u m we ld he o n l y s ys te m i n w h ic h T le. yc c t. Bes t d u t y l ues we re co r rec a l l s pec i f ied va
s a r k A wa rded to p m
( g rade A ) b y
iege r. h t m fo r u m.de / tes ts w w w .we r kze ug
Electrode TIG
11
New: H140 Ideal for electrodes up to 3.25 mm. 140 A and an outstanding duty cycle. Super lightweight. High duty cycle of 30% at 140 A. Simple to operate. Automatic adaptive hot start for perfect ignition. Anti-Stick system prevents electrode sticking. Arc force regulation provides support for difficult electrodes. Durable assembly design, insensitive to knocks, safety due to protection class of IP 23. High mains voltage tolerance, troublefree with long extension leads and good generators. Bears the S label denoting suitability for use in atmospheres subject to higher electrical risk. The standby system reduces fan noise, soiling and energy consumption. H 140, with mains cable, shock-proof plug, transportation belt Order no. 105.0140.0 (PG 12)
Method Electrode diameter Material electrode Recommended material thickness Welding range
1.5-3,25 mm Steel/stainless steel up to 8 mm 5-140 A
Duty cycle at max. current (40°)
30 %
Current at 60% duty cycle (40°)
110 A
Mains voltage
230 V
Weight
4.5 kg
Electrode
H 140 assembly pack All neatly tucked inside. With everything you need for electrode welding. H 140, with mains cable, shock-proof plug, transportation belt, 3 m electrode - and ground cable 16 mm2, slag hammer, wire brush, protection shield EN 166, welding glasses DIN 464647. Complete in a sturdy case with handy compartments. Order no. 105.0141.1 (PG 12) Model 2004 unit: 5.2 kg
12
Electrode welding
New: H150 Ideal for electrodes up to 4 mm. Higher powered with 150 A. Good for TIG welding. High performance reserves. Duty cycle of 40% at 150 A. Simple to operate. Automatic adaptive hot start for perfect ignition. Anti-Stick system prevents electrode sticking. Arc force regulation provides support for difficult electrodes. Switchover to TIG welding with ContacTIG ignition for good TIG welding. Durable assembly design, insensitive to knocks, safety due to protection class of IP 23. High mains voltage tolerance, troublefree with long extension leads and good generators. Bears the S label denoting suitability for use in confined spaces in atmospheres subject to higher electrical risk. The standby system reduces fan noise, soiling and energy consumption. H 150, with mains cable, shock-proof plug, transportation belt, order no. 105.0150.0 (PG 12)
Method
Electrode welding
TIG welding
Electrode diameter
1.5-4.0 mm
1.0-2.4 mm
Weldable material
Steel, stainless steel
Steel, stainless steel, copper
up to 10 mm
1-4 mm / copper 1-3 mm
5 – 150 A
5 – 150 A
Duty cycle at max. current (40°)
40 %
40 %
Current at 60 % DC (40°)
135 A
135 A
Recommended material thickness Welding range
Mains voltage
230 V
Weight
5.2 kg
Electrode TIG
H 150 assembly pack Everything you need for electrode welding on the move. An H 150, with mains cable, shock-proof plug, transportation belt, 3 m electrode - and ground cable 25 mm2, slag hammer, wire brush, protection shield EN 166, welding glasses DIN 4646-47. Complete in a sturdy case with handy compartments. Order no. 105.0151.1 (PG 12)
H 150 TIG assembly pack With everything you need for TIG and electrode welding. An H 150, with mains cable, shock-proof plug, transportation belt, 3 m electrode - and g round cable 25 mm2, slag hammer, wire brush, protection shield EN 166, welding glasses DIN 4646-47. Additionally with TIG set comprising: TIG valve torch WLV 17, 4 m; tungsten electrode, pressure reducer with volume and content manometer. All in a sturdy case with handy compartments. Order no. 105.0152.2 (PG 12)
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New: H180c
Enough power for electrodes up to 4 mm. Better TIG welding: 30 A more current plus gas management.
Professional electrode and TIG welding. High performance reserves with 150 A electrode and 180 A TIG current. High duty cycle of 40% at 150 A (electrode) and 30 % at 180 A (TIG). Automatic parameter system for simple operation: The microprocessor controls the ambient settings on the basis of the welding current and process status. Operator prompting using illuminated symbols. During electrode welding, automatic adaptive hot start for perfect ignition. Anti-Stick system prevents electrode sticking. Arc force regulation provides support for difficult electrodes. Switchover to TIG welding with ContacTIG ignition. Convenient TIG logic operation: The welding current and shielding gas are switched on and off using keys on the torch. No more breakaway of the arc at the end of welding. Automatic gas pre/post flow protects tungsten needle and welding seam from oxidation. 2 and 4 stroke logic for quick tacking and convenient seam welding. Automatic down-slope prevents quality impairing “end craters” at the end of the seam. Fast down-slope using 2nd torch key prevents fall-through of the seam in case of workpiece overheating. Durable assembly design, insensitive to knocks, safety due to protection class of IP 23. High mains voltage tolerance, troublefree with long extension leads and good generators. Bears the S label denoting suitability for use in confined spaces in atmospheres subject to higher electrical risk. The standby system reduces fan noise, soiling and energy consumption. Remote control facility. H 180c, with mains cable, shock-proof plug, transportation belt, order no. 105.0180.0 (PG 12)
Method
Electrode welding
TIG welding
Electrode diameter
1.5-4.0 mm
1.0-2.4 mm
Weldable material
Steel, stainless steel
Steel, stainless steel/copper
Recommended material thickness
up to 10 mm
Welding range
5 – 150 A
5 – 180 A
40 % / 150 A
30 % / 180 A
135 A
150 A
Duty cycle at max. current (40°) Current at 60 % DC (40°)
1-6 mm / copper 1-3 mm
Mains voltage
230 V
Weight
5.7 kg
Electrode TIG
H 180c assembly pack With everything you need for electrode welding on the move. An H 180c, with mains cable, shock-proof plug, transportation belt, 3 m electrode - and ground cable 25 mm2, slag hammer, wire brush, protection shield EN 166, welding glasses DIN 4646-47. Complete in a sturdy case with handy compartments. Order no. 105.0181.1 (PG 12)
14
H 180c TIG assembly pack With everything you need for TIG and electrode welding. An H 180c, with mains cable, shock-proof plug, transportation belt, 3 m electrode - and ground cable 25 mm2, slag hammer, wire brush, protection shield EN 166, welding glasses DIN 4646-47. plus TIG set, comprising: TIG torch WLT 17K, 4 m; tungsten electrode, pressure reducer with volume and content manometer, plug-in gas hose. Complete in a sturdy case with handy compartments. Order no. 105.0182.2 (PG 12)
New: H180t
HighEnd. Enough power for electrodes up to 4 mm. Even better TIG welding due to no-contact HF ignition.
Everything the H180c is capable of, plus no-contact HF and contacTIG ignition. Optimum TIG ignition. The tungsten needle makes no contact with the workpiece. Simply pressing a button ionises the arc channel and initiates the arc. Seams free of tungsten inclusions. Long service life of tungsten needles. Performance pure - 150 A electrode - and 180 A TIG current. Super duty cycle of 40% at 150 A (electrode) and 30 % at 180 A (TIG). Automatic parameter system for simple operation: The microprocessor controls the settings on the basis of the welding current and process status. Operator prompting using illuminated symbols. Convenient TIG sequence: Automatic gas pre/post flow protects the tungsten needle and welding seam from oxidation. 2 and 4 stroke logic for quick tacking and convenient seam welding. Automatic down-slope prevents quality impairing “end craters” at the end of the seam. Fast down-slope using 2nd torch key prevents fall-through of the seam in case of workpiece overheating. Automatic adaptive hot start for perfect ignition. Durable assembly design, insensitive to knocks, safety due to protection class of IP 23. High mains voltage tolerance, troublefree with long extension leads and good generators. Bears the S label denoting suitability for use in confined spaces in atmospheres subject to higher electrical risk. The standby system reduces fan noise, soiling and energy consumption. Remote control facility. H 180t, with mains cable, shock-proof plug, transportation belt , order no. 105.0185.0 (PG 12)
Method
Electrode welding
Electrode diameter
1.5-4.0 mm
Weldable material
Steel, stainless steel
TIG welding with HF ignition 1.0-2.4 mm Steel, stainless steel/copper
Recommended material thickness
up to 10 mm
Welding range
5 – 150 A
5 – 180 A
40 % / 150 A
30 % / 180 A
135 A
150 A
Duty cycle at max. current (40°) Current at 60 % DC (40°)
1-6 mm / copper 1-3 mm
Mains voltage
230 V
Weight
6.5 kg
Electrode TIG H 180t TIG assembly pack With everything you need for TIG and electrode welding stowed away neatly. The H 180t, mains cable with fitted shock-proof plug, operating manual. Additionally with 3 m electrode and ground cable 25 mm2, slag hammer, wire brush, protection shield EN 166, welding glasses DIN 4646-47, plus TIG set, comprising: TIG torch WLT 17K, 4 m; tungsten electrode, pressure reducer with volume and content manometer, plug-in gas hose. Complete in a sturdy case with handy compartments. Order no. 105.0187.2 (PG 12)
15
Accessories Accessories in detail
TIG wearing parts
Assembly wire feeder for all H models, empty Sturdy assembly wire feeder to hold the unit and one set of welding equipment. Order no. 610.0806.0, (PG 12)
Material
Autoprotect X 10+11 , protection level DIN 10. Converts to DIN 11. MIG-MAG /Electrode welding. Order no. 550.5311.0 (PG12) Autoprotect Flex 9-13 Protection level DIN 9 to 13. Electrode/MIG-MAG/ TIG. Dark/light switching. Sensor bar. Order no. 550.5312.0 (PG12) Autoprotect Multiflex 5-13 Protection level DIN 5 to 13. Electrode/MIG-MAG/TIG. Daylight filter, sensitivity regulator. Goes on where normal helmets give up the ghost. Order no. 550.5313.0 (PG12)
What you need for TIG welding H 150 TIG lift arc set WLV 17, TIG valve torch WLV17, 4 m Tungsten electrode, pressure reducer Order no. 104.9002.0 (PG12)
H 180c and H 180t TIG equipment WLT17 TIG torch WLT17 K, 4 m Tungsten electrode, pressure reducer, gas hose, ground cable 25 mm2, 4 m. Order no. 105.9001.0 (PG12)
TIG supplement H 180c and 180t as above, but without ground cable Order no. 105.9002.0 (PG12)
Foot remote control FR 35 with 5 m lead, switches welding current on and off, controls welding current intensity and down-slope. Order no. 570.1135.0 (PG14)
Equipment kits in case for TIG Kit 1 for 1.6 mm - WLT 17/26, 3 collets and collet bodies, 5 ceramic gas nozzles size 5;1 W electrode Order no. 551.3051.0 (PG2) Kit 2 for 2.4 mm - WLT 17/26, 3 collets and collet bodies, 5 ceramic gas nozzles size 6;1 W electrode Order no. 551.3052.0 (PG2)
16
Mat. thick- Dia. mm ness, mm tungsten electrode
Welding current, amperes
Size ceramic gas nozzle
Steel and st. steel
1.0 1.5 2.0 3.0 4.0
1.0 1.0-1.6 1.6 1.6-2.4 2.4
10-60 40-80 70-120 90-150 140-180
4 5 5 6 7
Copper and copper alloys
1.0 1.5 3.0
1.0 1.6 2.4
60-80 100-150 150-180
4 5 6
Ceramic gas nozzles for TIG torch WLV/WLT 17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 4 5 6 7
5 pcs. 5 pcs. 5 pcs. 5 pcs.
PG2 PG2 PG2 PG2
535.8003.4 535.8003.5 535.8003.6 535.8003.7
Collets for TIG torch WLV/WLT 17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 1.0 mm 1.6 mm 2.4 mm
5 pcs. PG2 5 pcs. PG2 5 pcs. PG2
535.8000.1 535.8000.2 535.8000.3
Collet body for TIG torch WLV/WLT17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 1.0 mm 1.6 mm 2.4 mm
2 pcs. PG2 2 pcs. PG2 2 pcs. PG2
535.8001.1 535.8001.2 535.8001.3
Tungsten electrode gold New-style, lathanised, with excellent ignition properties. Environmentally friendly. 100% radiation free, 175 mm. Size Pack Order no. 1.0 mm 1.6 mm 2.4 mm
10 pcs. PG2 10 pcs. PG2 5 pcs. PG2
535.8006.1 535.8006.2 535.8006.3
Clamping cap WLV/WLT17/26 short Replaces the standard torch cap in restricted spaces at the welding position. Order no. 535.8004.1 (PG2)
Clamping cap WLV/WLT17/26 long (standard) Replacement torch cap. Order no. 535.8004.2 (PG2)
TIG professional TIG Electrode
17
The new HT 180 AC/DC.
TIG Electrode
TIG Inverter HT 180 AC/DC. With transportation belt. Order no. 250.0181.1 (PG12) Available from September 2006 AC/DC: TIG for steel, stainless steel, aluminium and electrode welding. Despite the unmistakably handy design, the compact dimensions do nothing to compromise operating simplicity. Just ignite – immediate response – using minimal current, without touching the workpiece. Can be switched over for ContacTIG ignition. For an intensive, focused, quiet arc, minimal heat input, narrow seam. 2-stroke/4-stroke/spot function. Pulsing operation –FastPulse, even. Down-slope function using the 2nd torch button helps prevent “fall-through”. The welding current is now conveniently controlled directly at the torch. Simply connect the UP/DOWN torch. The variable alternating current frequency and balance take care of optimum aluminium results – something only big units have been able to offer in the past. Finally just a few words about adjustment. 3 inputs are all it takes – and the automatic parameterization system sets the optimum values for you. Fine tuning any time. From a perfect start to a perfect finish - a flawless seam without end craters.
Method TIG and electrode welding Electrode diameter TIG 1.0 – 3.2 mm Weldable material Steel, stainless steel/copper/aluminium Recommended material thickness 1 - 8 mm/ 1 - 3 mm/1 - 8 mm Electrode diameter Electrode 1.5 – 4.0 mm Welding range 3 - 180 A, DC + AC Adjustment Infinitely variable Duty cycle at max. current (40°C) 35 % Welding current at 60% DC (40°C) 140A Protection class IP23 Mains voltage 230 V Weight 13 kg Scope of delivery: HT 180 AC/DC with mains cable, shock-proof plug, transportation belt.
18
The new HT. More advantages.
Crash proof The unit is sitting on the workbench, someone knocks it down. Broken. A working day written off. Units which have adequate protection are not immediately recognizable. The standard stipulates 20 cm. Ever seen a 20 cm high table? We protect the HT at 9 crash points. Which is enough. After all, noone wants to tote a strong box.
Design – for practical purposes only. Appearing with a Lorch T under your arm says something about your professional attitude. Compact dimensions, recessed control panel. Logical functions and clearly arranged displays. Nothing to detract from the effective, ergonomic styling.
Just one of many useful details. A dedicated space for the cable, integrated in the handle and closed using Velcro tape. An end to cable spaghetti. And that irritating cable waiting to trip you up just in front of your foot has now gone. A detail – maybe. But these are just the points which add up to turn a good unit into a great one.
Dust is death to welding equipment. To some maybe – but not ours. We consider this classic trick to shorten the ser vice life of a welding unit to be somewhat below the belt. Dust spells the end for the power electronics. Inside coating, an extra cooling channel for the assemblies and the visible top filter are three answers which make for impro ved durability.
The trol ley. It places the welding unit at a safe and comfortable working height, while those generous and highly stable wheels make for optimized transport. Order no. 570.3035.0 (PG 12) The maxi trolley for additional 50l gas cylinders. Order no. 570.3036.0 (PG 12)
TIG equipment kit WLT 26 DD Complete equipment for TIG welding, comprising TIG torch WLT 26 DD, with double pushbutton. Ground cable 25 mm2, 4m; Pressure reducer with volume and content manometer, gas hose 1.8 m.
Hand remote control HR 30 For remote adjustment of the welding current. Complete with 5 m lead. Order no. 570.1031.0 (PG14)
SET WLT 26DD, 4 m long Order no. 569.2610.4, (PG 12) SET WLT 26DD, 8 m long Order no. 569.2610.8, (PG 12)
Extension cable set For extending the hand remote control lead. KSF 75, 7.5 m long. Order no. 570.9033.0 (PG14) KSF150, 15 m long. Order no. 570.9036.0 (PG14)
Complete equipment kit for TIG welding with remote control function at the torch. Comprising TIG torch WLT 26 UD, with double push button und up-down function for remote control of the welding current at the torch. Ground cable 25 mm 2.4m; Pressure reducer with volume and content manometer, gas hose 1.8 m.
Foot remote control FR 35 with 5 m lead, switches welding current on and off, controls welding current intensity and downslope by means of a foot pedal. Order no. 570.1135.0(PG14)
SET WLT 26 UD, 4 m long Order no. 569.2620.4, (PG 12) SET WLT 26 UD, 8 m long Order no. 569.2620.8, (PG 12)
Assembly case HT Sturdy transport case. Protects the unit and equipment. Order no. 610.0808.0 (PG12)
More accesoires on page 23
19
No one packs so much power smaller. The HANDY-TIG.
TIG
20
HANDY-TIG 210 DC
HANDY-TIG 210 AC/DC
The truth weighs just 8000 g, is 35 cm long, 13.8 cm wide and 32 cm high. That's all you n eed to know. Don't be fooled by anyone. You are looking at the smallest "fully professional TIG machine in the world" with some remarkable performance figures. Of course, we could have built it a bit heavier, bigger, with three knobs more and a handle to throw it away with. We would then have been deliberately fooling you, and you would have had to cart it around with you for the rest of your l ife, assuming it lasted that long. Its operation would also have been a little more difficult thanks to the (extra) knobs and you would have lost not only money but something much more important too: pleasure in your work. So HANDY-TIGs have all the essential qualities of t he best TIG welders. Non-contact HF ignition, comfortable TIG sequential logic, 180 A welding output and a duty cycle which allows even the longest of seams. Thanks to our secret SinePowerManagement, you won't lose this inverter output on a 230 V power supply because the mains fuse has blown. The arc is perfect. With steel, stainless steel, copper, aluminium and all conceivable alloys. Whether on a cable drum or generator. Naturally, our two HANDY-TIGs also permit welding with stick electrodes. Four basic settings, that's all you need, and this new friend will open up the world of TIG welding. Learn how to use it in only five minutes by simply turning the page. A glance at the accessories will only serve to whet your appetite.
Technical data
HANDY-TIG 210 DC
HANDY-TIG 210 AC/DC
TIG welding Electrode welding
TIG welding Electrode welding
1.0-2.4 mm
1.0-3.2 mm
Steel, stainless steel / copper
Steel, st. steel / copper /alum
1-6 mm / 1-3 mm
1-6 mm / 1-3 mm / 1-5 mm
Electrode diameter
1.5-4.0 mm
1.5-4.0 mm
Welding range
3-180 A, DC
3-180 A, DC + AC
Setting
inf. variable
inf. variable
Duty cycle at max. current (25°/40°)
30 % /15 %
40 % /25 %
Welding current at 60 % DC (25°/40°)
135 A/100 A
135 A /100 A
IP23
IP23
Mains voltage
230 V
230 V
Weight
8.3 kg
11.1kg
IP23
IP23
254.0210.0
254.1210.0
Method Electrode diameter TIG Weldable material Recommended material thickness
Protection class
Protection class Order number (PG12)
SCOPE OF DELIVERY: System complete with torch WLT 17 DD, 4 m; ground cable 25 mm2, 4 m; pressure reducer with volume and contents manometer, 4 m mains cable with shock-proof plug, fitted gas hose, operating manual
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The operation panel, 1:1 This is where the professional user will find all the necessary functions to optimise the work process. First time users will quickly get the hang of it too. Just 4 settings. And perfect “TIG welding” will soon become routine.
1. Welding current: Infinitely variable from 3 to 180 amperes.
2. Simple program selection with the Lorch inching logic system and LED display
3. Ignition current: infinitely variable from 7 to 180 amperes.
4. End current down-slope: Program controlled with correction controller.
Programm-Anzeige. Und los geht’s.
Program display. And off you go. Carefully engineered functions for optimum convenience. Direct current welding with 2stroke and 4-stroke control. Alternating current welding (HANDY-TIG 210 AC/DC) with 2-stroke and 4-stroke control. In DC operation, lift-arc contact ignition and HF ignition. In AC operation, (210 AC/DC) HF ignition. Automatic preflow and postflow. Down-slope using second torch button as a standard feature (prevents fall-through of the molten pool.) Programmed end current down-slope with correction controller for end crater filling. Optimised AC balance with perfect cleaning effect during aluminium welding. Automatic switchover to stick electrode welding when the TIG torch is unplugged. Program storage when changing between TIG and stick electrode welding. Polarity changeover by pressing a button for stick electrodes (210 AC/DC). Remote controllable. SinePowerManagement for maximum output at 230-V mains.
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Foot remote control FR 35 with 5 m lead, switches welding current on and off, controls welding current intensity and down-slope. Order no. 570.1135.0(PG14)
Extension cable set complete with cable plug and socket. For extending the hand remote control lead. KSF 75, 7.5 m long, Order no. 570.9033.0 (PG14) KSF 150, 15 m long. Order no. 570.9036.0 (PG14)
Hand remote control HR 30 for remote adjustment of the welding current, complete with 5 m lead. Order no. 570.1031.0 (PG14)
Assembly case HANDY-TIG. Study transport case. Protects the unit and equipment, even space for the Autoprotect helmet. Order no. 602.1227.0 (PG12)
Accessories for die HANDY-TIG
Autoprotect helmets. Electronic protective helmets for welders with high-speed darkening. Clear view for positioning the torch and welding wire. Darkens immediately on ignition. For details see page 68.
Autoprotect Flex 9-13, Protection level DIN 9 to 13. Electrode/MIG-MAG/TIG. Dark/light adjustment. Sensor bar. Order no. 550.5312.0, (PG12)
Autoprotect Multiflex 5-13 Protection level DIN 5 to 13. Electrode/MIG-MAG/TIG. Daylight filter, sensitivity regulator. Goes on where normal helmets give up the ghost. Order no. 550.5313.0, (PG12)
TIG welding rods are what make the actual joint. Their quality is fundamental to your welding results. Ensure that your welding rods match the material. All rods are 1000 mm long and packaged securely in a tube.
Aluminium AlMg 5 Filler metal for aluminium magnesium alloys. The welding seam area must be metallically bright. Suitable for base materials AlMg 3, AlMg 5, AlZnMg 1, cast alloys with Mg as the main alloy component. 100 rods, AlMg 5; 2.0 mm, Order no. 590.5020.4 (PG 12)
Aluminium Al 99.5 Filler metal for pure aluminium. The welding seam area must be metallically bright. Suitable for base materials Al 99.5, Al 99. 50 rods, 2.0 mm, order no. 590.5120.4 (PG 12) Top-quality TIG glove Supple leather for an optimum feel. Lightweight. Once you have worn them, you won’t want to take them off. Size M Order no. 535.8220.0 (PG 12) Size L Order no. 535.8220.1 (PG 12)
Electrode welding cable with electrode holder 25 mm2, 4 m long, with electrode holder and 13 mm connecting plug. Is required to weld electrodes. Order no. 551.0220.0 (PG 14)
Ground cables with ground clamp and plug Steady, reliable current transmission is imperative to a neat, tidy job. Defective or worn ground cables should be replaced in good time. The original HANDY-TIG cable is available as a spare. 25 mm2, 4 m long, plug 13 mm, order no. 551.0120.0 (PG14)
Aluminium AlSi 5 Filler metal for aluminium silicon alloys and for joining aluminium alloys of different types. The welding seam area must be metallically bright. Suitable for base materials AlMgSi 0.5, conditionally for AlMgSi 0.8 and AlMgSi 1 and for aluminium cast alloys up to 7 % Si. 100 rods, 2.0 mm, order no. 590.5220.4 (PG 12)
Stainless steel 1.4576 Filler metal for welding unstabilised and stabilised corrosion-proof Cr Ni-Mo steels for operating temperatures up to appr. 400°C. Suitable for base materials 1.4401, 1.4404, 1.4435, 1.4436, 1.4437, 1.4571, 1.4573, 1.4480, 1.4581, 1.4583 50 rods , 1.6 mm, order no. 590.5416.3 (PG 12) 50 rods , 2.0 mm, order no. 590.5420.3 (PG 12)
Stainless steel 1.4370 Filler metal for joints between non-alloyed and lowalloyed steels for operating temperatures up to appr. 300°C, cold tough to appr. –120°C. Suitable for joints between e.g. St 37-3 with 1.4301. 50 rods , 1.6 mm, order no. 590.5816.3 (PG 12) 50 rods, 2.0 mm, Order no. 590.5820.3 (PG 12)
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Torch and wearing parts for HANDY-TIG The original Lorch torch and original Lorch spares are essential components of a HANDY-TIG. There are people who think it is a good idea to produce copies of them. At first glance, you may well save a good 20 - 40% by buying these counterfeit copies. But you can rest assured they are made of cheaper basic materials. Otherwise there would be no profit margin for the plagiarists. After all, our spare parts are just as valuable and complex to produce as the system itself. You will pay for those cheaper spare par ts by higher wear, more working time and substandard welding results. Those are the facts.
Material
Thickn. mm Dia. mm
Steel and st. steel
TIG wearing parts To ensure optimum welding results, electrode diameters, welding current and gas nozzle must all be adjusted in line with the thickness. On the right is a table containing the relevant guideline values.
TIG torch for HT and HANDY-TIG Torch WLT 26DD, with 4 m hose set. Order no. 507.2640.0 (PG2) Torch WLT 26DD, with 8 m hose set. Order no. 507.2680.0 (PG2) TIG-UD torch with remote control only for the HT Torch WLT 26UD, with 4 m hose set. Order no. 507.2646.0 (PG2) Torch WLT 26UD, with 8 m hose set. Order no. 507.2686.0 (PG2)
Ceramic gas nozzles for TIG torch WLV/WLT17/26 To determine the corr ect size, see the explanation provided above. Size Pack Order no.
4 5 6 7
5 pcs. 5 pcs. 5 pcs. 5 pcs.
PG2 PG2 PG2 PG2
535.8003.4 535.8003.5 535.8003.6 535.8003.7
Collets for TIG torch WLV/WLT 17/26 To determine the corr ect size, see the explanation provided above. Size Pack Order no.
1.0 mm 1.6 mm 2.4 mm 3.2 mm
5 pcs. 5 pcs. 5 pcs. 5 pcs.
PG2 PG2 PG2 PG2
535.8000.1 535.8000.2 535.8000.3 535.8000.4
Collet body for TIG torch WLV/WLT17/26 To determine the corr ect size, see the explanation provided above. Size Pack Order no.
1.0 mm 1.6 mm 2.4 mm 3.2 mm 24
2 pcs. 2 pcs. 2 pcs. 2 pcs.
PG2 PG2 PG2 PG2
535.8001.1 535.8001.2 535.8001.3 535.8001.4
1.0 1.5 2.0 3.0 4.0-6.0 Copper and 1.0 copper 1.5 alloys 3.0 Aluminium 1.0 1.5 2.0 3.0 4.0 5.0
1.0 1.0-1.6 1.6 1.6-2.4 2.4-3.2 1.0 1.6 2.4 1.0 1.6 1.6 2.4 3.2 3.2
Ampere 10-60 40-80 70-120 90-150 140-180 60-80 100-150 150-180 10-60 40-80 70-120 90-150 140-180 170-180
Gas nozzle 4 5 5 6 7 4 5 6 4 5 5 6 7 7
Tungsten electrodes, gold New-style, lathanised, with excellent ignition properties. Long service life. Suitable for DC and AC. Environmentally friendly,100 % radiation free. Length: 175 mm. For matching diameters, see above table.
Diameter 1.0 mm 1.6 mm 2.4 mm 3.2 mm
Pack 10 pcs. 10 pcs. 5 pcs. 5 pcs.
Order no. 535.8006.1 535.8006.2 535.8006.3 535.8006.4
PG2 PG2 PG2 PG2
Tungsten electrodes, green Pure tungsten, for welding aluminium materials with AC. Good arc shape, very stable arc. Not for DC. Length 175 mm. For matching diameters, see above table.
Diameter Pack 1.0 mm 10 pcs.. 1.6 mm 10 pcs. 2.4 mm 5 pcs. 3.2 mm 5 pcs.
Order no. 535.8005.1 535.8005.2 535.8005.3 535.8005.4
PG2 PG2 PG2 PG2
Clamping cap WLV/WLT 17/26 short, for restricted space conditions. Order no. 535.8004.1 (PG2) Clamping cap WLV/WLT 17/26 long, standard torch cap, spare. Order no. 535.8004.2 ( PG2)
TIG accessory kit in case, for 2.4 mm- WLT 17/26, 3 collets and collet bodies, 5 ceram. gas nozzles size 6, 1 T electrode Order no. 551.3052.0 (PG2)
The Peak Tungsten electrodes which are not pointed and precision ground develop magnetic disturbance. Ignition problems and a migrating arc are the result. IMPORTANT: The Lorch Teg 4.0. The tungsten carbide grinding machine. After all, you don’t use an axe to sharpen your pencils.
All electrode sizes with diameters of 1 to 4mm can be ground. Electrodes which are as shor t as 15mm, or are badly eroded or damaged with spatter, can be handled.
Clear view of the grinding process.
Diamond grinding wheels with 3 longlasting grinding surfaces. Adjusted by means of a handle.
Precision grinding finish. Accurate electrode guidance. The grinding angle can be varied from 15° - 180°. Only 0.3mm of material surface is removed. Grinding dust is removed by an integral filter unit, ensuring the health and safety of the operator.
Speed infinitely variable 28,000 rev/min. power 850 W, 230 V, diamond wheel 40 mm dia., weight 2.8 kg . Complete assembly in a neat carrying case. Order no. 810.8600.0 (PG 12) Stationary arrest mechanism Order no. 810.8606.0(PG 12)
Grinding wheel dia. 40 mm Electrode holder Collet chuck dia. 1.0 mm Collet chuck dia. 1.6 mm Collet chuck dia. 2.0 mm Collet chuck dia. 2.4 mm Collet chuck dia. 3.2 mm Collet chuck dia. 4.0 mm Filter cassette Viewing window Disposable filter bag
Order no. 810.8601.0 810.8602.0 810.8603.0 810.8603.1 810.8603.2 810.8603.3 810.8603.4 810.8603.5 810.8604.0 810.8608.0 810.8605.0
PG 12 12 12 12 12 12 12 12 12 12 12
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TIGknowledge
A very intense and focused arc is produced during TIG welding. The advantages are a minimum introduction of heat, narrow seam and welding without filler metals. Only the base material fuses with itself leading to perfect quality visible welds. Very small currents can be set with good TIG inverters, thus enabling the welding of very thin materials. Industry and trade have been making money with the advantages of TIG welding for a long time. Whenever demands such as leakproof, safe for foods, visible, etc. are placed on a weld seam, irrespective of whether stainless steel or aluminium are used, TIG is the solution. TIG machines used to be big and cumbersome. Moreover, their setting was complicated and their purchase price high. However, the increased use of stainless steel and aluminium means that metalworking companies are having to turn to TIG welding – including on building sites.
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TIG welding for you. Which is why we have developed our HANDY inverters to spare you any problems. Small, lightweight and handy. Therefore easy to use, because a lot of what you previously had to set has been integrated during their development as “artificial intelligence”. Each machine is designed for welding from a 230 V lighting mains. Since anything which is good sells easily, we have consistently been able to lower the price. But what do you get out of this technology? Mobility. For workshop and construction. Final assembly of stainless steel railings, aluminium facings and similar tasks can be performed “outdoors” without any problems. Nor do you have to mask off large areas, spattering is a thing of the past. Everything is lighter, smaller and easier to handle. Convincing advantages over the “heavyweight” rivals. You drastically reduce finishing work, because the look and quality of your seam is perfect. As we said: TIG earns you money.
What else do you have to know. There is a choice of DC and AC welding. DC welding is used for steel, stainless steel and copper, AC for aluminium and magnesium. A further important difference is the ignition method: you choose between noncontact HF ignition and contact ignition, also called lift-arc ignition. During contact ignition the tungsten electrode is placed on the workpiece - a low current flows, the system switches over to the welding current by raising the electrode slightly, the arc is ignited. The advantages of this method are a low purchase price and no interference with other electronic devices through HF. However, there is the risk that tungsten impurities will remain on the workpiece, which can lead to corrosion. During HF (= High-frequency) ignition the tungsten electrode is kept at a distance. Short HF pulses ionise the air gap between electrode and workpiece. The arc ignites. An absolutely professional ignition method. When all is said and done, anyone who does without TIG technology today is not doing himself a favour, because TIG welding has become simpler.
Another handy tip for everyday TIG welding A frequent mistake people make is incorrect handling of t he tungsten electrode. With direct current (DC) welding, the electrode must be ground to a point lengthways relative to the current flow direction. Even grinding ridges should be polis-
hed away. Anyone omitting to do this will experience magnetic faults leading to considerable ignition problems and an instable light arc. For alternating current (AC) welding, up to a diameter of 1.6 m, electrodes do not require grinding, although for electrodes over this diameter, a chamfer is required, naturally also in the longitudinal direction.
This is the only way to ensure a narrow light arc and a neat seam which is not too wide. The Lorch Teg 4.0 tungsten electrode grinding machine is the ideal way to keep your electrodes in tip-top condition. Guaranteed to eliminate ignition problems and arc instability. For details, turn back a page.
Shielding gases used for TIG welding
For all melting materials
Argon 4.6 / 99.996% Argon
I1 as per DIN EN 439
For all melting materials
Argon 4.8 / 100 % Argon
I1 as per DIN EN 439
Nickel-based alloys, copper, aluminium argon-helium mixtures 30 % He, rest Argon 50 % He, rest Argon 70 % He, rest Argon
I3 as per DIN EN 439
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Anyone who needs to weld with 5 mm thick electrodes opts for the ISI. Switchover facility from 230 V to 400 V. Electrode TIG
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ISI 5 CL There are lighter, smaller electrode inverters than the ISI 5 CL, some are even cheaper. But is there a better one? Order no. 115.0051.0 (PG12)
A milestone in the history of converter construction. The ISI 5 CL combines the “ideals” of electrode welding like no other machine we make. This inverter miracle has maximum voltage reserves thanks to the generously dimensioned Power-Mos power module and high-speed arc control, combined with a complex ripple filter. This all adds up to a very stable DC arc, which in turn means better welding than many others! Every location and position. Not forgetting the 6 selectable current programs, an extraordinary thin sheet pulse from 0.8 mm and a patented power circuit. This is very unusual for an inverter, but unbelievably useful: it allows you to switch from 230 to 400 V. A feature which knows no limits. Make it ISI – buy ISI.
Method Electrode diameter (electrode/TIG)
Electrode welding/TIG welding 1.5-5.0 mm/1.0-3.2 mm
Material
Steel/stainless steel
Rec. material thickness (electrode/TIG)
up to12 mm/1-6 mm
Welding range (electrode/TIG) Current at 60% duty cycle (25°/40°) Setting Mains voltage
3-200 A/3-220 A 200A/170A stepless 230/400V
Scope of delivery: Unit with mains cable with CEE-16 plug, mains adaptor 230V/400V with shock-proof plug, operating manual. High no-load voltage, infinitely variable current adjustment, 6 different welding programs: normal, soft, hot start 1 + 2, arc-force, thin sheet pulse. Dropped seam-proof, patented mains switchover 1~230 V/3~400 V, compensation of mains fluctuations, remotecontrollable. S mark, approved for use in small rooms with a higher electrical risk, sturdy construction with a dust-proof encapsulated control area, conforms with EN 60974-1, CE mark. TIG welding with additional TIG valve torch and pressure reducer: manual gas control via valve in torch handle. Accessories Welding accessories SPA 35 mm2/ plug 13, professional welding equipment, 35mm≈ highly flexible welding cable (2 x 4 m) with electrode holder and ground clamp, protection shield EN 166, welding glasses DIN 4646-47, wire brush and slag hammer Order no. 550.5504.0 (PG14)
Transportation belt Simplifies transport on site. Complete set with fixings. Order no. 570.4100.0 (PG12)
What you need for TIG welding TIG lift arc set WLV 26/3550, comprising TIG valve torch WLV26, 4 m; tungsten electrode 2.4 mm, pressure reducer with volume and content manometer. Order no.104.9005.0 (PG12)
Extension cable set complete with cable plug and socket. For extending the hand remote control lead. KSF 75, 7.5 m long, Order no. 570.9033.0 (PG14) KSF 150, 15 m long, Order no. 570.9036.0 (PG14)
Hand remote control HR 30 for remote adjustment of the welding current, complete with 5 m lead. Order no. 570.1031.0 (PG14)
Accessories for TIG on page 41 29
Revered as a legend among welding machines. The CL.
Electrode
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CL 4 P-F just
CL 5 P-F just
Our classics. A blueprint for our rivals and equipment used by over 100,000 men on this continent. For business, workshop and building site – to date we have built a total of 177,021 units. However legends only arise by constantly paying tribute to the truth. This, as we all know, is found on the inside of welding machines. Ours contain all of our experience. It would have been stupid to alter the housing, you would only have had to pay for this, and it would only have misled you. Because there’s nothing wron g with the ergonomics and a fibreglass-reinforced polyester housing is indestructible, never rusts and is fully insulated. The housing will never be “live” in the event of defects or if dropped or incorrectly connected on building sites. The CL today is as good as it ever was. As the transformer and inductor are of copper, the only way to achieve the right ignition and welding properties. The working point can be ideally set for both machines. This is guaranteed by 11 settings for the CL 4 P-F and an infinitely adjustable control with toroidal core inductor in the CL 5 P-F. This allows a fast and comfortable adjustment to changing welding positions. The excellent duty cycles are achieved with a powerful intensive fan cooler. The ergonomically arranged controls are always within reach and easy to read from a distance. The thermocontrol, an overload protection with warning display, provides additional safety. Every CL can be switched over from 230 V lighting mains to 400 V 3-phase mains and the welding cables can be removed with a quick-action coupler. We hope that this meets all of your needs.
CL 4 P-F
CL 5 P-F
Electrode welding
Electrode welding
1.5-4.0 mm
1.5-5.0 mm
Steel/stainless steel
Steel/stainless steel
Rec. material thickness
1-10 mm
1-12 mm
Welding range
20-175 A
25-200 A
Duty cycle at max. current (25°/40°)
60 % /40 %
60 % /40 %
Current at 60% duty cycle (25°/40°)
175 A/145 A
200 A/170 A
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Infinitely variable welding current setting in a single revolution
Mains voltage
230/400 V
230/400 V
Order no. (PG 12)
106.5005.0
106.5007.0
Method Electrode diameter Material
Settings
Scope of delivery: Unit with mains cable with CEE-16 plug, mains adaptor 230 V/400 V with shock-proof plug, operating manual.
To match: Complete set of welding accessories. SPA 25 mm / plug 13, professional welding accessories 25 mm2, highly flexible welding cable (4 m + 3 m) with electrode holder and ground clamp, protection shield EN 166, welding glasses DIN 4646/4647, wire brush and slag hammer, order no. 550.5503.0 (PG14) 2
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Important! Wh of weld seam
Labour Wages and salaries account for 76 cm of the overall costs
32
at does 1metre really cost?
Gas 9 cm
Electric Wire power 6 cm 4 cm
Unit 5 cm is what your welding unit costs. Acquisition, depreciation, interest.
This is something we should all give some
Realistically 76 cm working time
So perhaps now you are closer to under-
thought to. Compared to the costs of labour,
As a rule, a “talented welder” will put in a
standing a typical Lorch precept: Better
fuel and consumables, the purchase of a
good 1,907 hours a year. If he uses a less
good and sound than bad and unreliable.
new welding unit pales into insignificance.
talented welding unit which reduces his
But the tendency is to concentrate on the
work input by just 8%, that makes 152.56
price of the machine and forget what hap-
hours lost. But if we assume an hourly
pens next. Particularly if we look at labour
wage of 17.90
costs, which can be pushed through the
2,730.80
roof by choosing the wrong, cheap welding
this type of welding equipment is written
equipment. Think about it: At Lorch we
off on average over five years means the
build welding machines designed to make
whole deal will cost you 13,654.-- € on top.
your work and your life easier. And for this
Not to mention the effect on your nerves.
€
€
an, that adds up to
every year. And the fact that
we charge you a whole 5 cm.
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One for all TIG MIG-MAG Electrode MIG-brazing
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The A and the ACuSi. All in one. 3 steps to perfect welding. SmartBase guides you easily through all tasks. Up to 4 processes run easily through your hand. Faster, more mobile, lighter and better than the rest. Once you own one of the new A series from Lorch, you will be able to forget needing a B or indeed any other system. Because these models will supply you with the perfect workshop MIG-MAG unit which you can take around and about with you without even thinking. 19 kg of high-end inverter technology certainly won’t weigh you down. And it can withstand some pretty rough treatment. In the past there were two options when it came to working on site: Either “costly” welding using electrodes which meant swallowing higher additional material costs, more work chipping slag and slower welding speeds - or else the inconvenience of lugging a heavy workshop unit or even the precious pulse inverter with you. The tough competitive climate means you can’t afford option one, option two is impracticable. Which as far as we are concerned, just leaves the A. Really good MIG-MAG welding with infinitely variable adjustment from bottom to top. The wire speed is automatically adjusted. Steel, stainless steel or aluminium. Really good MIG-MAG welding without gas. Thanks to its amazingly simple equipment, MIG-MAG welding works in the open air using gasless wire. Just like a normal wire spool. Forget scaling the scaffolding clutching a gas cylinder. These wires contain a special powder which generates gas and slag in the same way as with electrode welding. Really good TIG welding. Outstanding ignition and welding characteristics for TIG-DC with steel and stainless steel. Really good electrode welding. The welding characteristics are perfect for electrode welding too. Because of the high output, the A 1700 is easily capable of welding with 4 mm electrodes. And the A 2200 even copes with 5 mm electrodes. And with the ACuSi: Really good MIG brazing. At long last here is a method of professionally joining galvanised and steel sheet without damaging the corrosion protection. MIG brazing is a process which takes place only at 800°C. Minimal heat, negligible voltage, practically no distortion. And the ACuSi is ideal for use on brazing robots too. Infinitely variable MIG-MAG inductor for steel stainless steel aluminium Intervention in the automatic system for individual fine tuning
Precision wire speed adjustment
3.
For TIG down-slope
Current and voltage setting digitally displayed
Digitally displayed
1. Select MIG-MAG, TIG electrode
TIG 2Press once for stroke Spots slower up-slope and down-slope, 4Interval perfect seam start Select stroke no end craters diameter of with TIG welding wire pulsing tungsten needle stick electrode
2.
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The A offer TIG, MAG-MAG and electrode
A 1700 0.8 wire MIG-MAG, 150 A TIG, electrode 4 mm. 230V. 19 kg on site Order no. 201.1700.0 (PG 12)
A 2200 1.0 wire MIG-MAG, 200 A TIG, electrode 5 mm. 230/400V. 20 kg on site Order no. 201.2200.0 (PG 12)
A Welding range MIG-MAG infinitely variable DC at max. current (40°) Current at 60 % DC (40 °) Mains voltage Weldable wires steel/aluminium Material MIG-MAG Recommended material thickness steel / aluminium Welding range TIG/electrode DC at max. current (40°) TIG/electrode Current at 60 % DC (40 °) TIG/electrode Electrode diameter TIG/electrode Weldable material TIG/electrode Recommended material thickness for TIG Recommended material thickness for electrode Weight
MIG-MAG without gas. These wires contain a special powder which generates gas and slag. A simple resetting job.
A 1700 A 2200 35 - 170 A 35 – 220 A 25 % / 170 A 15 % / 220 A 120 A 170 A 230 V 230 V / 400 V 1 Ph 0.6-0.8 mm / 1.0 mm 0.6-1.0 mm / 1.0 mm Steel / stainless steel / aluminium 0.8-5 mm / 2-3 mm 0.8–8 mm / 2-5 mm 5–150/25-150A 5-200/25-200A 35 %/30% 35 %/30 % 130/120 A 170/170 A 1.0-2.4/1.5-3.25 mm 1.0-3.25 mm/1.5-5.0 mm Steel, stainless steel, with TIG also copper 1-4mm/copper 1-3 mm 1-6 mm/copper 1-4 mm up to 10 mm up to 12 mm 19 kg 20 kg
Scope of delivery: Torch ML 1500, 4 m Torch ML 2400, 4 m Shock-proof plug, Shock-proof plug, CEE-32 plug Ground cable 25 mm2, 4 m; pressure reducer, basket coil adapator, mains cable 4 m, gas hose.
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The A offer TIG, MIG-MAG, electrode and MIG-brazing
A 1700 CuSi 0.8 wire MIG-MAG, 150 A TIG, electrode 4 mm. 230 V. 19 kg on site. Order no. 201.1710.0 (PG 12)
A 2200 CuSi 1,0 wire MIG-MAG, 220 A TIG, electrode 5 mm. 230/400 V on site. Order no. 201.2210.0 (PG12)
ACuSi Welding range MIG-MAG infinitely variable DC at max. current (40°) Current at 60 % DC (40 °) Mains voltage Weldable wires steel/aluminium Material MIG-MAG Recommended material thickness steel / aluminium Welding range TIG/electrode DC at max. current (40°) TIG/electrode Current at 60 % DC (40 °) TIG/electrode Electrode diameter TIG/electrode Weldable material TIG/electrode Recommended material thickness for TIG Recommended material thickness for electrode Weight
A 1700 CuSi A 2200 CuSi 35 - 170 A 35 – 220 A 25 % / 170 A 15 % / 220 A 120 A 170 A 230 V 230 V / 400 V 1 Ph 0.6-0.8 mm / 1.0 mm 0.6-1.0 mm / 1.0 mm Steel / stainless steel / aluminium 0.8-5 mm / 2-3 mm 0.8–8 mm / 2-5 mm 5–150/25-150A 5-200/25-200A 35 %/30% 35 %/30 % 130/120 A 170/170 A 1.0-2.4/1.5-3.25 mm 1.0-3.25 mm/1.5-5.0 mm Steel, stainless steel, with TIG also copper 1-4mm/copper 1-3 mm 1-6 mm/copper 1-4 mm up to 10 mm up to 12 mm 19 kg 20 kg
Scope of delivery: Torch ML 1500, 4 m Torch ML 2400, 4 m Shock-proof plug, Shock-proof plug, CEE-32 plug Ground cable 25 mm2, 4 m; pressure reducer, basket coil adapator, mains cable 4 m, gas hose.
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MIG-MAG accessories A 1700, A 2200 and CuSi Ergonomics, a highly flexible hose set, wear-proof torch neck and optimum current transmission all interact in these torches to ensure optimum welding characteristics and a service life that pays dividends.
A 1700 torch ML 1500, 3 m long, order no. 503.1500.3 (PG2) ML 1500, 4 m long, order no. 503.1500.4 (PG2) When using for MIG brazing, brazing torch set order no. 551.2015.0 is additionally required
A 2200 torch ML 2400, 3 m long, order no. 503.2400.3 (PG2) ML 2400, 4 m long, order no. 503.2400.4 (PG2)
Conversion kit aluminium, 1.0 or 1.2 mm. Combination teflon liner with flangemounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. For torches up to 4 m. Order no. 551.2014.0 (PG2) Conversion kit stainless steel, 0.6/0.8/1.0 mm Combination carbon - teflon liner with flange-mounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. For torches up to 5 m. Order no. 551.2015.0 (PG2)
When using for MIG brazing, brazing torch set order no. 551.2015.0 is additionally required
Liners ML 1500, ML 1500 PM Liners ML 2400, ML 2400 PM Liner for steel wire 0.6 - 0.9 mm, colour code blue For 3 m torch, (PG02), order no. 535.8300.1 For 4 m torch, (PG02), order no. 535.8300.2
A 1700 PowerMaster torch ML 1500 PM, 3 m long, order no. 503.1501.3 (PG2) ML 1500 PM, 4 m long, order no. 503.1501.4 (PG2) When using for MIG brazing, brazing torch set order no. 551.2015.0 is additionally required
A 2200 PowerMaster torch ML 2400 PM, 3 m long, order no. 503.2401.3 (PG2) ML 2400 PM, 4 m long, order no. 503.2401.4 (PG2) When using for MIG brazing, brazing torch set order no. 551.2015.0 is additionally required
PowerMaster torch. Regulate power and speed by remote control in the torch itself.
38
Liner for steel wire 1.0 - 1.2 mm, colour code red For 3 m torch, (PG02), order no. 535.8300.3 For 4 m torch, (PG02), order no. 535.8300.4
Contact tips for torch, ML 1500 + ML 1500 PM, PG2 Design Pack Order no. 0.6 mm M6 5 535.8101.1 0.8 mm M6 5 535.8101.2 1.0 mm M6 5 535.8101.3 For aluminium wire 1.0 mm M6 5 535.8101.5 1.2 mm M6 5 535.8101.6 Contact tips for torch, ML 2400 + 2400 PM, PG2 0.6 mm M6 5 535.8106.1 0.8 mm M6 5 535.8106.2 1.0 mm M6 5 535.8106.3 For aluminium wire 1.0 mm M6 5 535.8106.5 1.2 mm M6 5 535.8106.6 Retaining springs for gas nozzles, PG2 For ML 1500 + PM 10 535.8100.9 Contact tip holders, PG2 For ML 2400 + PM 2 535.8120.4 Gas diffuser, PG2 For ML 2400 + PM 2 535.8120.3 Plug-in gas nozzles, for torch ML 1500 + PM, PG2 Tapered gas nozzle 3 535.8100.1 Cylindrical gas nozzle 3 535.8100.2 Spot gas welding nozzle 3 535.8100.3 Plug-in gas nozzles, for torch ML 2400 + PM, PG2 Tapered gas nozzle 3 535.8120.1 Cylindrical gas nozzle 3 535.8120.2
Original equipment kit for torch ML 1500, 3 m Kit including the most important torch wearing parts at an affordable all-in price. Contains: 1 tapered gas nozzle, 1 spot gas welding nozzle, 5 contact tips 0.8 mm, 1 liner blue 0.6-0.9 mm, 3 retaining springs, 1 Lorch separating spray 400 ml. Order no. 551.1021.0 (PG2)
MIG-MAG welding wire
Original equipment kit for torch ML 2400, 3 m Kit including the most important torch wearing parts at an affordable all-in price. Contains: 1 tapered gas nozzle, 1 spot gas welding nozzle, 5 contact tips 1.0 mm, 1 liner red 1.0-1.2 mm, 1 contact tip holder, 1 Lorch separating spray 400 ml. Order no. 551.1024.0 (PG2)
SG2, 1.0 mm for welding unalloyed steel. Standard spool K300, 15 kg, Order no. 590.0010.4 (PG12)
SG2, 0.8 mm for welding unalloyed steel. Small spool D200, 5 kg, Order no. 590.0008.1 (PG12)
SG2, 0.8 mm for welding unalloyed steel. Standard spool K300, 15 kg, Order no. 590.0008.6 (PG12)
AlMg5, 1.0 mm for welding aluminium. Small spool D200, 2.0 kg, Order no. 590.0410.0 (PG12) AlMg5, 1.2 mm for welding aluminium. Small spool D200, 2.0 kg, Order no. 590.0412.0 (PG12)
Torch original equipment kit Containing the different accessory kits - but packaged safely and neatly in a sturdy plastic case with handy compartments Order no. 551.0490.1 (PG12) for ML 1500, just Order no. 551.0490.3 (PG12) for ML 2400
Set of torch wearing parts for ML 1500 Case containing the following main wearing parts. 3 tapered gas nozzles, 10 contact tips 0.8 mm, 10 retaining springs. Order no. 551.1508.0 (PG12)
Set of torch wearing parts for ML 2400 Case containing the following main wearing parts : 3 tapered gas nozzles, 10 contact tips 1.0 mm, Order no. 551.2524.0 (PG12)
1.4316, 0.8 mm for welding stainless steel (V2A). Small spool D200, 5.0 kg, Order no. 590.0208.1 (PG12)
Cored wire for welding without shielding gas 0.9 mm dia. For low-alloyed sheet materials up to 15 mm. Small spool D 200, 4.5 kg Order no. 590.0200.9 (PG 12)
High-grade brazing wires ACuSi CuSi3-wire for galvanised sheet 0.8 mm, small spool D200, 5 kg, order no. 590.1008.1 (PG 12) 0.8 mm, basket coil K 300, 15 kg, order no. 590.1008.3 (PG 12) 1.0 mm, small spool D200, 5 kg, order no. 590.1010.1 (PG 12) 1.0 mm, basket coil K300, 15 kg, order no. 590.1010.3 (PG 12) CuAl8 wire for stainless steel 0.8 mm, small spool D200, 5 kg, order no. 590.1108.1 (PG 12) 0.8 mm, basket coil K 300, 15 kg, order no. 590.1108.3 (PG 12) 1.0 mm, small spool D200, 5 kg, order no. 590.1110.1 (PG 12) 1.0 mm, basket coil K300, 15 kg, order no. 590.1110.3 (PG 12)
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MIG-MAG accessories A 1700, A 2200 and CuSi The original Lorch torch and original Lorch spares are essential components of an A. There are people who think it is a good idea to produce copies of them. At first glance, you may well save a good 20 - 40% by buying these counterfeit copies. But you can rest assured they are made of cheaper basic materials. Otherwise there would be no profit margin for the plagiarists. After all, our spare parts are just as valuable and complex to produce as the system itself.
Adaptor for basket coils K300 Included in the scope of supply of the A models. Spares: Order no. 551.9020.0 (PG12) Adaptor for small spools For using plastic spools with a 200 mm diameter. Spacer guarantees reliable wire feed. Order no. 620.9650.0 (PG 12) Feed rolls A 1700 and A 2200 For steel/stainless steel wires 0.6 / 0.8 mm Order no. 620.8700.0 (PG12) For steel/stainless steel wires 0.8 / 1.0 mm Order no. 620.8701.0 (PG12) For steel/stainless steel wires 1.0 / 1.2 mm Order no. 620.8710.0 (PG12) For Aluminium and brazing wires 0,8/1,0 mm Order no. 620.8701.1 (PG 12) For aluminium wires 1.0 /1.2 mm Order no. 620.8710.1 (PG12) Lorch separating spray 400 ml Forms a thin protective film in the gas nozzle to protect against sintering of hot weld splashes. Order no. 551.9000.0 (PG2)
MIG-MAG protective gloves Made of high-grade, durable leather. With wear-resistant seam. What a real welder’s glove should look like. Order no. 535.8210.0, (PG12)
Special pliers MIG-MAG 4 functions. Cutting the welding wire. Cleaning the shielding gas nozzle. Pulling off the gas nozzle. Releasing the contact tip. Order no. 535.8225.1 (PG12)
Electrode welding cable with electrode holder 25 mm2, 4 m long, with electrode holder and 13 mm connecting plug. Is required to weld electrodes. Order no. 551.0220.0 (PG 14)
40
Ground cables With ground clamp and plug. Another case where quality counts. Steady, reliable current transmission is imperative to a neat, tidy job. Defective or worn ground cables really do have to be replaced. A 1700 and A 2500 25mm2, 4m, plug 13mm, Order no.551.0120.0 Autoprotect X 10+11, protective level DIN 10. Converts to DIN 11. MIG-MAG/electrodes welding. Order no. 550.5311.0 (PG12) Autoprotect Flex 9-13, protective level DIN 9 to 13. Electrode/ MIG-MAG/TIG. Dark/light switching. Sensor bar. Order no. 550.5312.0 (PG12) Autoprotect Multiflex 5-13 protective level DIN 5 to 13. Electrode/ MIG-MAG/TIG. Daylight filter, sensitivity regulator. Keeps going where other helmets give up the ghost. Order no. 550.5313.0 (PG12)
TIG accessories A 1700, A 2200, and CuSi The electrode diameter, welding current and gas nozzle should be adapted to the material thickness. See the table below.
Material
Thickn.
Dia. mm
Ampere
1.0 1.0-1.6 1.6 1.6-2.4 2.4-3.2 1.0 1.6 2.4 1.0 1.6 1.6 2.4 3.2 3.2
10-60 40-80 70-120 90-150 140-180 60-80 100-150 150-180 10-60 40-80 70-120 90-150 140-180 170-180
Steel and st. steel
1.0 1.5 2.0 3.0 4.0-6.0 Copper and 1.0 copper 1.5 alloys 3.0 Aluminium 1.0 1.5 2.0 3.0 4.0 5.0
Gas nozzle 4 5 5 6 7 4 5 6 4 5 5 6 7 7
Tungsten electrodes, gold New-style, lathanised, with excellent ignition properties. Long service life. Suitable for DC and AC. Environmentally friendly,100 % radiation free. Length: 175 mm. For matching diameters, see above table.
Diameter 1.0 mm 1.6 mm 2.4 mm 3.2 mm
Pack 10 pcs. 10 pcs. 5 pcs. 5 pcs.
Order no. 535.8006.1 535.8006.2 535.8006.3 535.8006.4
PG2 PG2 PG2 PG2
Clamping cap WLV/WLT 17/26 short, for restricted space conditions. Order no. 535.8004.1 (PG2) Clamping cap WLV/WLT 17/26 long, standard torch cap, spare. Order no. 535.8004.2 (PG2)
Ceramic gas nozzles for TIG torch WLV/WLT 17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 4 5 6 7
5 pcs. 5 pcs. 5 pcs. 5 pcs.
PG2 PG2 PG2 PG2
535.8003.4 535.8003.5 535.8003.6 535.8003.7
Collets for TIG torch W LV/WLT 17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 1.0 mm 1.6 mm 2.4 mm 3.2 mm
5 5 5 5
pcs. pcs. pcs. pcs.
PG2 PG2 PG2 PG2
535.8000.1 535.8000.2 535.8000.3 535.8000.4
Collet body for TIG torch WLV/WLT 17/26 To determine the correct size, see the explanation provided above. Size Pack Order no. 1.0 mm 1.6 mm 2.4 mm 3.2 mm
2 pcs. 2 pcs. 2 pcs. 2 pcs.
PG2 PG2 PG2 PG2
535.8001.1 535.8001.2 535.8001.3 535.8001.4
TIG torch for the A 1700 Torch WLT 17EA, with 4 m hose set. Order no. 507.1460.4 (PG2) Torch WLT 17EA, with 8 m hose set. Order no. 507.1460.8 (PG2) TIG torch for the A 1700 Torch WLT 26EA, with 4 m hose set. Order no. 507.2660.4 (PG2) Torch WLT 26EA, with 8 m hose set. Order no. 507.2660.8 (PG2)
TIG welding rods are what make the actual joint.
Stainless steel 1.4576 Filler metal for welding unstabilised and stabilised corrosionproof Cr Ni-Mo steels for operating temperatures up to appr. 400°C. Suitable for base materials 1.4401, 1.4404, 1.4435, 1.4436, 1.4437, 1.4571, 1.4573, 1.4480, 1.4581, 1.4583 50 rods, 1.6 mm, order no. 590.5416.3, (PG 12) 50 rods, 2.0 mm, order no. 590.5420.3, (PG 12)
Stainless steel 1.4370 Filler metal for joints between non-alloyed and low-alloyed steels for operating temperatures up to appr. 300°C, cold tough to appr. –120°C. Suitable for joints between e.g. St 37-3 and 1.4301. 50 rods , 1.6 mm, order no. 590.5816.3, (PG 12) 50 rods, 2.0 mm, order no. 590.5820.3,(PG 12)
TIG accessory kit 1 in case, for 1.6 mm WLT 17/26, 3 Collets and collet bodies, 5 ceramic gas nozzles size 5, 1 T electrode Order no. 551.3051.0 (PG2) TIG accessory kit 2 in case, for 2.4 mm- WLT 17/26, 3 collets and collet bodies, 5 ceram. gas nozzles size 6, 1 T electrode Order no. 551.3052.0 (PG2)
41
Read befo % B C
Discount it!
Brand quality
Right then. You have really decided to buy
The tendency in this category is for manufac-
yourself a welding system. Great. Question is
turers to have nothing but the rating plate
- which one? Sales people will promise you
Brand quality
from all over the place. This is how B quality
the world. Rumour has it some of them have never even held a welding torch. How can
So from now on you will place your trust in
brand systems are produced today. They are
they possibly offer you any sensible advice?
good, solid brand names. A product that has
300 Euros cheaper, they weld - and the hous-
Like someone without a licence giving an
been around a long time can’t be all bad. Or
ing looks highly professional. The apprentice
“expert” opinion about cars.
can it? You are bound to know lousy busi-
will just love it. But it is in the fine tuning
ness people who have been around forever
that everything falls apart. The specified
against all the odds. Sometimes investors
amperage loses all credibility after warm-up,
can find themselves paying just for a label.
and certainly defies any sensible measure-
They pay no attention to the inner values of
ment. Just one example: The latest B systems
their purchase. Market share, sales opportu-
come with low-cost control systems from
nities and what not are all more important.
Chechnya. Unable to believe the price, we got
So as not to confuse you completely, let us
hold of one. Once we opened it up, all was
just say two sentences thing about C brand
revealed. Simplistic technology. Set to age in
quality: It comes from outside of Europe,
a few months at the outside. Sending the
These are the types you will encounter most-
and the lion’s share of the costs you pay
wire feed off balance, causing the free burn
ly where everything revolves around price.
goes towards sales commission and freight.
time of 20/100th of a sec. to shoot to 0.5
This is where you will see those tempting
Don’t be surprised to see a white elephant
secs., meaning a continuous problem with
offers. X Euros! and a money back guarantee
walking past your workshop.
nozzle burnout. So you limp along for anoth-
if undersold. So you buy. You take it home
er 2 or 3 years until one day: total failure.
and you start welding. The seam stays in one
Part price just 100 Euros. Telephone call 2
piece, and from that day forward you firmly
Euros. Outage 10 days. But then, you did pay
believe that this is how a welding system is
a whole 198 Euros less to start with. No. In
simply meant to be. It stutters its way
actual fact the work quality and time lost
through life. But then, you paid just 1,000
with this stone age technology has already
Euros. Actually you were rel ieved of 1,000
cost you a lot more than you realise.
Euros. The follow-up costs can mount alarmingly if you work with it professionally. The thing is useless and good only for the scrap heap. This is known as the % category. Now you realise there must be real brand names around too. And there are.
42
made in Germany. Everything else comes
re you buy Recommendation: As far as we are concerned, in Germany there are three welding system producers you can safely buy from if work quality, satisfaction, durability and added value mean anything to you. One of those is Lorch. German made through and trough. And so we move on to an impressive name right off the top of the A list. As early as the compa-
A
Brand quality
But maybe the secret lies in the production, too. Only recently an automatic coating plant was introduced for electronic systems which is faster than anything before it. The Lorch gang worked for a whole month to slow it down. We need say no more about
ny’s foundation in 1957, development was
to developing a new welding system to ben-
quality.
seen as the number one foundation stone for
efit users, our engineers and application
The manufacture of a Lorch system is
the future. The photo showing strength test-
technology team have free rein. As much
something that just won’t be rushed. If we
ing by standing a truck on a polyester hous-
material as they need. Time too. Which
used more housings made of plastic, we
ing, gives you some idea of how things were
there is plenty of in tiny Auenwald. From
could cut 21 minutes off the assembly time.
the concept to the analogue and digital cir-
But we stick with steel and with staff who
cuits, from the system software to that one
understand about assembly precision - not
essential screw - everything is created
everybody does.
here. Because only what we build ourselves
All dealer orders and queries are processed
can we be sure will work. And what we
online. All requests are answered. Final
don’t know, we fetch home to Auenwald
inspection is fully computer automated. The Lorch high-bay warehouse is linked to the outside world by bar code. But when it
done back then. Positive scepticism has been
comes to production itself, tradition is king.
ingrained in the Lorch gang ever since. By
You could call it painstaking precision - and
far and away the first to introduce plastic
it is precisely this that makes a Lorch sys-
housings to the market back then. Other
tem better than anything else you can buy.
manufacturers are still claiming this as
But in the final reckoning, there is one
highly innovative today. But things look very
main beneficiary in all this: You. And you will go on reaping the benefits for years to with the cooperation of universities and
come. One of Lorch’s fundamental princi-
specialist institutes. In the beginning is
ples: In Auenwald, nobody tells lies.
always the idea. Followed by electronic tests and fundamental experiments, then the prototype. Which is when the going gets tough. Modify. Weld. Modify. Weld. Around the clock. For weeks. Finally whole different at Lorch in the 21st century. South
systems end up on the scrap heap.
German Auenwald is home to what must be
Sometimes even whole projects. The sys-
Europe’s most modern welding system facto-
tems which demonstrate the greatest level
ry. Logistics pure. But one thing has not
of success under development are pro-
changed: Everyone is still preoccupied with
duced and launched into the marketplace.
welding. And the heady enthusiasm of those
Where they hardly ever meet their match
early pioneers has never left. When it comes
among comparable products of their day.
43
MIG-MAG
M stands for masterpiece. The 2000 series.
44
“The 2nd M series has taken on a cult status. The MIG-MAG welding system for thin sheet and lightweight steel construction.
Why is it exactly that the world and its wife would rather be driving a Mercedes than an Opel? Looks better? More status? Is that all? Just ask a taxi driver. A cabby will make a professional judgement based on hard business sense. After all, he drives it. Or why is it that a hammer drill will slice through the concrete in just 3 seconds where others plug away for 15 seconds to make the same sized hole? Nobody who drills for a living would put themselves through that. It is no different if you look at our M system. If you are a professional you have no choice but to opt for this degree of MIG-MAG perfection. An amateur who does the odd bit of welding can save a good 400 Euros by shopping around for some sort of welding system. We don’t supply this particular market and we never will. An M from Lorch offers inner values - values we set out to achieve at an enormous cost in terms of time and effort.
Example 1 90 % of all welding systems fall short of the specified output level once they have completed the warm-up phase. If the rating plate says 350 amperes, chances are that will only apply to a cold start. After just 5 minutes, the output takes a nose dive - but stealthily. In other words while you are welding.
This type of behaviour can drive a professional welder round the bend. An M will go on giving just what we promise it will after hours. And years. Example 2 It is generally true that the sum of all details is what sets an object apart from the rest. Take a look at just one such detail - the knob next to the wire insertion. This is something you will be lucky to find on any other unit. But actually it is an ingenious detail. It allows you to insert the wire without picking up the torch. This unassuming looking knob is used to switch the wire feed then and there. Without it, the whole process becomes an imprecise science as your eyes move backwards and forwards between the torch switch and the wire feed roll. This knob with its surround costs us around 12 Euros. Others don’t bother with it, although they are perfectly aware of its benefits. Savings like this allow them to shave more off the purchase price. Good for them.
Example 3 Underneath every welding system are casters. Available to manufacturers in different qualities ranging in price from 10 Euros for a set of four up to 98 Euros. The question every producer asks is: How much do I invest in the bit you don’t see? Most decide this is a place they can afford to cut corners. Of course they roll. But efficient braking is quite a different matter. And they struggle over obstacles and around corners. At Auenwald, these are the sort we mount under our waste paper bins. We don’t see any other valuable purpose for them. The other group among our competitors opt for casters with a k ick-stop brake.
Still a bit hit and miss, but cheap. And with a professional look. Great. True, they do brake the unit on a sloping workshop floor. But then there is the braked swivel caster you see her e. You will find it under every single M. Expensive, but worth it. Guaranteed to stay solid as a rock in your trailer at the back. If you don’t want your precious unit to fly off you had better tie it down.
Example 4 The easiest way to fool the average craftsman is by palming him off with a cheap control system. Why? Because it costs a fraction and looks just the same. But after just a short time these cheap imitations will show signs of wear and tear. Your wire feed is thrown off balance, resulting in a shift in the free burning time. The result: nozzle burnout. The “best bit”: At first you assume that you are at fault. You never really realise what is going on. Even when the whole control system packs up within four years at the outside. 80% of all systems offered in the marketplace today fall under this category. Every M comes with a microcontroller. No wear. Precise, digital control of every single function. Our industrial systems all work to this high engineering standard. The best currently available. So you see - there are welding systems and welding systems. The choice is yours.
45
The basis of every M. From the 2020 to the 2095. 6 output models from 140 to 350 ampere. With up to 24 settings. Also with 4-roll drive. Lid opening to the side for improved access. Fully insulated inner floor to protect the welding wire basket against phase to ground short circuits. Absolute feed precision - more accurate pressure setting, no wire deformation, precise wire alignment and wire transport. Special wire inlet guides made of moulded brass to ensure easier running for steel and stainless steel as well as aluminium. Sophisticated electronics, compact central torch connection, adjustable wire roll brake, even easier operation and new, ergonomic outside front. A transformer-inductor combination which is of course copper-wound and ideally matched. A sturdy diode rectifier with overvoltage protection. Switching stages for optimum working points in every position. MIG-MAG logic, which controls the electronic welding current, feed, wire burn-back, gas postflow and spot welding time. Fully adjustable spot welding time. Air cooling for a higher duty cycle. Thermocontrol as overload protection. Horizontal wire spool take-up, suitable for large and small spools with no extra adaptor. Removable ground cable with quick-action coupler. Galvanised sheet steel housing with powder-coated front and sides. Integrated gas cylinder holder and compliance with the standards EN 60974-1 a, CE and S marks.
MIG-MAG
M 2020 All accessories included
M 2040 All accessories included
M 2060 All accessories included
Ideal for thin-sheet welding e.g. on vehicles
Ideal for thin-sheet welding and profile work
Ideal for thin-sheet welding and light steel work
MIG-MAG welding
MIG-MAG welding
MIG-MAG welding
30-140 A
25 -170 A
25 - 210 A
6
6
6
Duty cycle at max. current (25°/40°) 25 % /15 %
25 % /15 %
25 % /15 %
Welding current at 100% DC (25°/40°) 70 A/55 A
90 A/70 A
105 A/85 A
Weldable wires, steel
0.6-0.8 mm
0.6-0.8 mm
0.6-1.0 mm
1.0 mm
1.0 mm
1.0-1.2 mm
230 V
230 / 400 V
230/ 400 V
Steel/stainless steel/aluminium
Steel/stainless steel/aluminium
Steel/stainless steel/aluminium
0.8-3 mm
0.8-5 mm
0.8-8 mm
2 mm
2-3 mm
2-5 mm
0.6 mm/0.8 mm
0.6 mm /0.8 mm
0.6 mm/0.8 mm
202.2020.1
202.2040.1
202.2060.1
Method Welding range Settings
Weldable wires, aluminium Mains voltage Material Material thickness, steel Material thickness, aluminium Set wire diameter Order number (PG12) Scope of delivery:
46
System complete with torch System complete with torch ML 1500, System complete with torch ML1500, ML 1500, 3 m; ground cable 3 m; ground cable 25 mm2, 4 m, 3 m (torch ML 2500 for top 25 mm2, 4 m, pressure reducer with pressure reducer with volume and performance range), ground volume and content manometer, content manometer, mains cable 4 m with cable 25mm 2, 4m, pressure reducer with mains cable 4 m with schock-proof plug, CEE16-plug, mains adaptor 230V/400V volume and content manometer, mains cable fitted gas hose, with schock-proof plug, fitted gas 4 m with CEE 16-plug, mains adaptor operating manual. hose, operating manual. 230V/400V with schock-proof plug, fitted New: with basket coil adaptor New: with basket coil adaptor gas hose, operating manual. as standard. as standard. New: with basket coil adaptor as standard.
M 2080 All accessories included
M 2090, with 4-roll feed All accessories included
M 2095, with 4-roll feed All accessories included
All-round system for sheet and light to medium steel work
All-round system for sheet and medium steel work
All-round system for sheet and medium steel work
MIG-MAG welding
MIG-MAG welding
MIG-MAG welding
30 - 230 A
30 - 290 A
25 - 350 A
7
12
24
30 % /20 %
30 % /20 %
30 % /20%
140 A/115 A
160 A/135 A
185 A/160 A
0.6-1.0 mm
0.6-1.2 mm
0.6-1.2 mm
1.0-1.2 mm
1.0-1.2 mm
1.0-1.6 mm
400 V
400 V
400 V
Steel/stainless steel/aluminium
Steel/stainless steel/aluminium
Steel/stainless steel/aluminium
0.8-10 mm
0.8-12 mm
0.8-15 mm
2-6 mm
2-8 mm
2-12 mm
0.8 mm/1.0 mm
0.8 mm/1.0 mm
0.8 mm/1.0 mm
202.2080.1
202.2090.1
202.2095.1
System complete with torch ML 2500, 3 m; ground cable 25 mm2, 4 m, pressure reducer with volume and content manometer, mains cable 4 m with CEE 16-plug, fitted gas hose, operating manual. New: with basket coil adaptor as standard.
System complete with torch ML 2500, 3 m, ground cable 25 mm2, 4 m, pressure reducer with volume and content manometer, mains cable 4 m with CEE 16-plug, fitted gas hose, operating manual. New: with basket coil adaptor as standard.
System complete with torch ML 3600, 3 m; ground cable 35 mm2, 4 m, pressure reducer with volume and content manometer, mains cable 4 m with CEE 32-plug, fitted gas hose, operating manual. New: with basket coil adaptor as standard.
More accessories on page 50
47
M 3000. Middle and heavy weight champion. Ideal with automatic adjustment.
MIG-MAG When you buy a Lorch system we will provide all the knowledge you need. Page 79.
48
M 3050 With or without wire feeder
M 3070 With or without wire feeder
The M for medium and heavy-duty steel work. It copes not just with thick, but thin too. As a compact system or with a separate wire feeder. An out-and-out workhorse, designed to cope with the tough all-round demands of your workshop. They all come with the same high-powered precision 4-roll feed which allows individual adjustment of pressure on the roll pairs. This is the only way to guarantee trouble-free welding of all types of wire. The housing is just as stable as the gas cylinder holder. The transformer-inductor power unit features such a finely tuned 24-step power characteristic that the ideal arc is achieved for every conceivable welding assignment. And the M series comes with a duty cycle ready to do some serious work. But the feature our development boys (and 1 girl) are most proud of has to be the totally re-engineered control system. This degree of operating con venience, functional scope and durability is an all-time first in this machine category. Take the new processor-controlled automatic adjustment for instance. The control system automatically controls the wire feed in line with the selected step. A mere touch of the correction button is enough to optimise the feed rate. The active inductor system adjusts automatically too. High-end technology from the prize-winning C-dialog takes care of minimal spatter ignition and excellent light arc characteristics. This is how easy good welding ought to be. And when it comes to functions, the M has everything covered: 2-stroke, 4-stroke, spot and interval welding. Adjustable spot and interval times. Ignition feed regulation, adjustable automatic free burning system and the knob for powerless wire insertion. The safety switch device prevents unwanted wire transport. And the stand-by function - also a standard feature - helps save energy and reduces dirt and noise. Because the fan and water cooling system are only started when they are really needed. In systems with wire feeder, you regulate the wire speed and wire feed on the spot. Which allows you to concentrate on what you are doing instead of walking backwards and forwards to the unit. In water-cooled systems, an exemplary centrifugal pump operates on demand and keeps noise to a minimum. Caution: In most cases, cheap water-cooled oscillating piston pumps are used, causing vibration in the hose set and then in the torch. And their durability leaves something to be desired. Compliance with standard EN 60974-1; CE and S marks. In short: This is everything the perfectionist needs. And anyone who owns an M 3000 qualifies as one of those.
Welding range/ settings DC at max. current (25/40°) Current at 100 % DC (40 °) Mains voltage Weldable wires steel / alum Material MIG-MAG Recommended material thickness steel / alum. Set wire Torch type (gas/water) Compact system, gas Compact system, water Feeder system, gas, 1m interm. hose set Feeder system, gas, 5m interm. hose set Feeder system, gas, 10m interm. hose set Feeder system, water, 1m interm. hose set Feeder system, water, 5m interm. hose set Feeder system, water, 10m interm. hose set Other lengths on request.
M 3050
M 3070
25-350A/2x12 settings 45%/30%/350 A 210 A 3x400 V 0.6-1.6 mm / 1.0-1.6 mm Steel / stainless steel / aluminium from 0.8 / from 2 mm 1.0 / 1.2 mm ML 3600 / MW 5500 203.3500.0, PG 12 203.3510.0, PG 12 203.3500.1, PG 12 203.3500.5, PG 12 203.3501.0, PG 12 203.3510.1, PG 12 203.3510.5, PG 12, 203.3511.0, PG 12
30-400A/2x 12 settings 45%/30%/400A 240 A 3x400 V 0.6-1.6 mm / 1.0-1.6 mm Steel / stainless steel / aluminium from 0.8 / from 2 mm 1.0 / 1.2 mm - / MW 5500 203.3710.0, PG 12
203.3710.1, PG 12 203.3710.5, PG 12 203.3711.0, PG 12
Scope of delivery: System, torch with 4 m hose set, ground cable 50 mm 2, 4 m long, pressure reducer, basket coil adaptor K 300, mains cable 4 m with CEE 32 plug, gas hose. With feeder systems, the connection set is ready mounted.
49
Accessories
for the
M 2000 M 3000
Autoprotect X 10+11 Fixed protective level DIN 10. Can be converted for fixed protective level DIN 11 using the supplied spare glass. Reasonably priced, tough autoprotect helmet for MIG-MAG and electrode welding. Not suitable for TIG welding. Solar cells mean the helmet is always ready for service without the need for a battery change. Order no. 550.5311.0, (PG12)
Autoprotect Flex 9-13 With adjustable protective level from DIN 9 to 13, providing reliable protection and an optimum view for electrode, MIG-MAG and TIG welding. Convenient adjustment from outside. The light-dark switching time can be set as required, e.g. to protect eyes against weld afterglow. The detachable sensor bar allows you to eliminate the influence of the ambient light and also ensure reliable darkening in all welding positions. Solar cells, without battery. Order no. 550.5312.0, (PG12)
Autoprotect Multiflex 5-13 Highlight. Protective level DIN 5 to 13. Electrode, MIG-MAG and TIG. Sensors and daylight filters detect the arc, and the sensitivity regulator controls response in every welding situation. Wherever “normal” helmets give up the ghost: low welding current, fast arc changes, welding around corners with concealed arc, reflective surfaces - you can rely on the Autoprotect Multiflex to stay safely darkened. Adjustable delay time opening to prevent dazzle by weld glow. Grinding mode – clear vision for grinding. Solar cells, without battery. Order no. 550.5313.0, (PG12)
Lorch coolant LCL 20 For water-cooled welding units. Frost protection to –20°C. To combat cooling system corrosion and for lubrication. Combats pump seizure. 5 litres, order no. 551.9006.5 (PG 12) 25 litres, order no. 551.9006.9 (PG 12)
50
and
series.
Lorch separating spray 400 ml Forms a thin protective film in the gas nozzle to protect against sintering of hot weld splashes. Only ever spray into the nozzle from the side, never from the front, as this can clog up the gas outlet apertures on the neck of the torch. Order no. 551.9000.0 (PG2)
Special pliers MIG-MAG 4 functions in a single tool. Cutting the welding wire. Cleaning splashes off the shielding gas nozzle. Pulling off the gas nozzle Releasing the contact tip. For torch ML 1500, ML 2500, Order no. 535.8225.1 (PG12) For torch ML 3600, MW 5500, Order no. 535.8226.1 (PG12)
MIG-MAG protective gloves Manufactured to the specifications of the Lorch specialists. Made of high-grade, durable leather. With wear-resistant seam. This is what a real welder’s glove should look like. Order no. 535.8210.0, (PG12)
Wire brush, 3 rows of bristles, Order no. 550.5210.0 (PG12)
Wire brush, VA, 3 rows of bristles, Order no. 550.5211.0 (PG12)
Ground cables With ground clamp and plug. Another case where quality counts. Steady, reliable current transmission is imperative to a neat, tidy job. Defective or worn ground cables really do have to be replaced. M 2020 to M 2090 25mm2, 4 m, plug 13 mm, order no.551.0120.0 M 2095 35mm2, 4 m, plug 13 mm, order no.551.0130.0 M 3050 and 3070 50mm2, 4 m, plug 13 mm, order no.551.0140.0 all (PG14)
Trolley for wire feeders There are plenty of us who would appreciate the con venience of not having to carry our wire feeder. We can thoroughly recommend this way of easing the work load - by letting the wheels take the strain. Chassis KE 80, Order no. 570.3024.0 (PG 12)
Feed rolls The feed rolls for the wire feed units have to be adapted in line with the welded wire. The necessary equipment is listed in the technical data.
MIG-MAG welding wire
SG2, 0.8 mm for welding unalloyed steel. Small spool D200, 5 kg, Order no. 590.0008.1 (PG12)
SG2, 0.8 mm for welding unalloyed steel. Standard spool K300, 15 kg, Order no. 590.0008.6 (PG12)
SG2, 1.0 mm for welding unalloyed steel. Standard spool K300, 15 kg, Order no. 590.0010.4 (PG12)
SG2, 1.2 mm for welding unalloyed steel. Standard spool K300, 15 kg, Order no. 590.0012.4 (PG12)
Feed rolls M 2020 to M 2080 For steel/stainle ss steel wires 0.6 / 0.8 mm Order no. 620.8700.0 (PG12) For steel/stainless steel wires 0.8 / 1.0 mm Order no. 620.8701.0 (PG12) For steel/stainless steel wires 1.0 / 1.2 mm Order no. 620.8710.0 (PG12)
AlMg5, 1.0 mm for welding aluminium. Small spool D200, 2.0 kg, Order no. 590.0410.0 (PG12) AlMg5, 1.2 mm for welding aluminium. Small spool D200, 2.0 kg, Order no. 590.0412.0 (PG12)
For aluminium wires 1.0 /1.2 mm Order no. 620.8710.1 (PG12) 1.4316, 0.8 mm for welding stainless steel (V2A). Small spool D200, 5.0 kg, Order no. 590.0208.1 (PG12)
Feed rolls for M 2090, M 2095, M 3050, M 3070 Where 4-roll drive is used for these units, 2 feed rolls are always required. Please remember when ordering.
For steel/stainle ss steel wires 0.6 / 0.8 mm Order no. 620.8940.0 (PG14) For steel/stainless steel wires 0.8 / 1.0 mm Order no. 620.8709.0 (PG14) For steel/stainless steel wires 1.0 / 1.2 mm Order no. 620.8941.0 (PG14) For steel/stainless steel wires 1.2 / 1.6 mm Order no. 620.8942.0 (PG14) For aluminium wires 1.0 /1.2 mm Order no. 620.8953.0 (PG14)
Adaptor for small spools This adaptor is required when working with plastic spools with a 200 mm dia. It is used as a spacer and guarantees reliable wire feed. Order no. 620.9650.0 (PG 12)
Adaptor for basket coils K300 basket coil adaptor K300 is required for placing basket coils into the wire roll fixture. This is included in the scope of delivery of the M series. To order spares: Order no. 551.9020.0 (PG12)
For aluminium wires 1.2 /1.6 mm Order no. 620.8954.0 (PG14)
51
Accessories
for the
M 2000 M 3000
Original equipment kit for torch ML 1500, 3 m Kit including the most important torch wearing parts at an affordable all-in price. Contains: 1 tapered gas nozzle, 1 spot gas welding nozzle, 5 contact tips 0.8 mm, 1 liner blue 0.6-0.9 mm, 3 retaining springs, 1 Lorch separating spray 400 ml. Order no. 551.1021.0 (PG2)
and
series.
Torch original equipment kit in a case Each case containing the different accessory kits shown on the left - but packaged safely and neatly in a sturdy plastic case with handy compartments.
Order no. 551.0490.1 (PG12), for ML 1500 Order no. 551.0490.2 551.0490.2 (PG12), for ML 2500 Order no. 551.0490.4 551.0490.4 (PG12), for ML 3600 Order no. 551.049 551.0491.0 1.0 (PG12), for MW 5500
Original equipment kit for torch ML 2500, 3 m Kit including the most important torch wearing parts at an affordable all-in price. Contains: 1 tapered gas nozzle, 1 spot gas welding nozzle, 5 contact tips 1.0 mm, 1 liner red 1.0-1.2 1.0-1.2 mm, 3 retaining springs, 1 contact tip holder, 1 Lorch separating spray 400 ml.
Set of torch wearing wearing parts for ML 1500 1500 Case containing the following main wearing parts . 3 tapered gas nozzles, 10 contact tips 0.8 mm, 10 retaining springs. Order no. 551.1508.0 (PG12)
Order no. 551.1023.0 (PG2)
Original equipment kit for torch ML 3600, 4 m Kit including the most important torch wearing parts at an affordable all-in price. Contains: 1 tapered gas nozzle, 1 cylindrical gas nozzle, 5 contact tips 1.0 mm , 1 contact tip holder, 1 gas diffuser, 1 liner red 1.0-1.2 mm, 1 Lorch separating spray 400 ml. Order no. n o. 551.1036.0 551.1036.0 (PG2)
Set of torch wearing parts for ML 2500 Case containing the following main wearing parts : 3 tapered gas nozzles, 10 contact tips 1.0 mm, 10 retaining springs. Order no. 551.2510.0 (PG12)
Set of torch wearing parts for ML 3600 Case containing the following main wearing parts : 3 tapered gas nozzles, 10 contact tips 1.0 mm, 1 contact tip holder, 1 gas diffuser. Order no. 551.2136.0 (PG12)
Original equipment kit for torch MW 5500, 4 m Kit including the most important torch wearing parts at an affordable all-in price. Contains: 3 tapered gas nozzles, 5 contact tips 1.2 mm, 1 contact tip holder, 1 gas diffuser, 1 liner 1.0-1.2 mm, 1 Lorch separating spray 400 ml. Order no. n o. 551.1055.0 551.1055.0 (PG02)
52
Set of torch wearing parts for MW 5500 Case containing the following main wearing parts 3 tapered gas nozzles 10 contact tips 1.0 mm 10 contact tips 1.2 mm 1 contact tip holder 1 gas diffuser. Order no. 551.2155.0 (PG12)
Only original complete burners from Lorch Ergonomics, a highly flexible hose set, wear-proof torch neck and optimum current transmission all interact in these torches to ensure optimum welding characteristics and a service life that pays dividends.
Torch ML 1500 for the M 2020, M 2040, M 2060 ML 1500, 3 m long, order no. 503.1500.3 503.1500.3 (PG2) ML 1500, 4 m long, order no. 503.1500.4 503.1500.4 (PG2)
Conversion kit aluminium How to convert your torch for welding aluminium wire 1.0 / 1.2 mm. Kit contains: Special combination teflon liner with flange-mounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. The set can be used for torches up to 4 m in length. To prevent wire damage, we recommend using 1.2 mm wire with a 3 m torch. Please order the matching contact tips and aluminium feed rolls separately. Order no. 551.2014.0 (PG2)
Torch ML 2500 for the M 2080, M 2090 ML 2500, 3 m long, order no. 503.2500.3 (PG2) ML 2500, 4 m long, order no. 503.2500.4 (PG2) ML 2500, 5 m long, order no. 503.2500.5 (PG2) Conversion kit stainless steel, 0.6/0.9 mm How to convert your torch for welding stainless steel wire. Kit contains: Special combination carbon-teflon liner with flangemounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. The set can be used for torches up to 5 m in length. Please order the matching contact tips and aluminium feed rolls separately. Order no. 551.2015.0 (PG2) Torch ML 3600 for the M 2095, M 3050, gas-cooled ML 3600, 3 m long, order no. 503.3600.3 (PG2) ML 3600, 4 m long, order no. 503.3600.4 (PG2) ML 3600, 5 m long, order no. 503.3600.5 (PG2)
Torch MW 5500 for the M 3050, M 3070, water-cooled MW 5500, 3 m long, order no. 503.5500.3 (PG2) MW 5500, 4 m long, order no. 503.5500.4 (PG2) MW 5500, 5 m long, order no. 503.5500.5 (PG2)
Conversion kit stainless steel, 1.0/1.2 mm How to convert your torch for welding stainless steel wire 1.0 / 1.2 mm Kit contains: Special combination PA liner with flange-mounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. The set can be used for torches up to 5 m in length. Please order the matching contact tips and aluminium feed rolls separately. Order no. 551.2015.2 (PG2)
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Accessories M 2000 M 3000
Contact tips for torch, ML 1500, (PG02) Design
Pack
Order no.
0.6 mm M6
5
535.8101.1
0.8 mm M6
5
535.8101.2
1.0 mm M6
5
535.8101.3
1.0 mm M6
5
535.8101.5
1.2 mm M6
5
535.8101.6
For aluminium wire
Spare torch necks to fit: ML 1500 also f. MS15, order no.535.8400.1 (PG02) ML 2500 also f. MS25, order no.535.8400.2 (PG02) ML 3600 also f. ML36, order no.535.8400.4 (PG02) MW 5500 order no.535.8400.5 (PG02)
Contact tips torch, ML 2400, 2500, 3600, (PG02) 0.6 mm M6
5
535.8106.1
0.8 mm M6
5
535.8106.2
1.0 mm M6
5
535.8106.3
1.2 mm M6
5
535.8106.4
1.0 mm M6
5
535.8106.5
1.2 mm M6
5
535.8106.6
For aluminium wire
Liners for ML 1500, ML 2500, ML 3600 Also to fit MS 15, MS 25, ML 36 Liner for wire 0.6 - 0.9 mm, colour code blue For 3 m torch, (PG02), order no. 535.8300.1 For 4 m torch, (PG02), order no. 535.8300.2 Liner for wire 1.0 - 1.2 mm, colour code red For 3 m torch, (PG02), order no. 535.8300.3 For 4 m torch, (PG02), order no. 535.8300.4 For 5 m torch, (PG02), order no. 535.8300.5
Contact tips for for torch, MW 5500, (PG02) 0.8 mm M8
10
535.8108.
1.0 mm M8
10
535.8108.3
1.2 mm M8
10
535.8108.4
1.0 mm M8
10
535.8108.5
1.2 mm M8
10
535.8108.6
For ML 1500
10
535.8100.9
For ML 2500
10
535.8105.9
For aluminium wire
For gas nozzles, (PG02)
Contact tip holders, (PG02) For ML 2500
2
535.8106.9
For ML 3600
2
535.8107.2
For MW 5500
2
535.8108.9
For ML 3600
2
535.8107.3
For MW 5500
2
535.8108.8
Gas diffuser, (PG02) Liners for MW 5500 , Wire 1.0 - 1.2 mm For 3 m torch, (PG02), order no. 535.8301.0 For 4 m torch, (PG02), order no. 535.8302.0 For 5 m torch, (PG02), order no. 535.8303.0
Gas nozzles, plug-in, for torch ML 1500, (PG02) Tapered gas nozzle
3
535.8100.1
Cylindrical gas nozzle
3
535.8100.2
Spot gas nozzle
3
535.8100.3
Gas nozzles, plug-in, for torch ML 2500, (PG02) Tapered gas nozzle
3
535.8105.1
Cylindrical gas nozzle
3
535.8105.2
Spot gas nozzle
3
535.8105.3
Gas nozzles, plug-in, for torch ML 3600, (PG02) Tapered gas nozzle
3
535.8107.0
Cylindrical gas nozzle
3
535.8107.1
Gas nozzles, plug-in, for torch MW 5500, (PG02)
54
Tapered gas nozzle
2
535.8109.0
Cylindrical gas nozzle
2
535.8109.1
To date it all revolved around MIG-MAG. Corrosion protection and higher-strength steel sheet are ringing the changes. What next? MIG-brazing
MIG-MAG
55
The Lorch M 3030 automotive. MIG brazing and MIG-MAG in one. The answer to the stream of new materials and regulations. Whoever processes high quality steel today buys the M 3030 automotive. The future demands it. A combined MIG brazing and MIG-MAG welding unit is the logical solution. Up until now it was all simple sheet. Little thought was given to the quality of properties required from high quality thin sheet welding or the newly introduced MIG brazing (MSG brazing). Customer demands are changing to being more strict and specific. For example: incorrect welding or brazing on/at a vehicle may result in a delayed activation of the airbag, sheet structure or corrosion resistance may be destroyed. Already today, MSG brazing is mandatory in every Opel workshop. Tailored blanks, modern high strength steels and the benefits of MIG brazing are making your welding machine obsolete. High strength steels are all set to take over in the future. Times have changed. MIG brazing units are already an established feature in wide-ranging fields such as the automotive industry, steel furniture manufacture, container construction and many more. MIG brazing is a hard soldering technique in which the required process energy is generated by an electrical arc. A MIG-MAG welder will easily get to grips with it. Instead of steel wire, the arc melts a solder wire. The process temperature is well below that needed for MIG-MAG. Sheet is not melted, the solder creates a firm joint that is gentle on the material. The benefits of MIG brazing include minimal material distortion and low heat generation. Ideal for thin sheet. No change occurs in the base material. Strength is uncompromised. Welding state-of-the-art materials. No corrosion of the brazing seam. In coated sheet, the zinc coating remains undamaged even in the brazing seam zone. Corrosion resistance is guaranteed without the need for any subsequent treatment. Optimum gap bridgability. Minimal spatter and a soft brazing seam reduce the need for reworking. So if thin sheet is an issue for you, the M 3030 automotive awaits. As far as we are concerned, its cost-to-performance ratio among available systems is second to none. Method
MIG brazing/MIG-MAG welding
Brazing-/ Welding range 30 – 260 A / 11.4 – 27 V Settings 41 Digastep performance steps Duty cycle at max. current (40°) 35 % at 260 A Welding current at 60 % DC (40°) 200 A Welding current at 100 % DC (40°) 160 A Weldable wires steel 0.6 - 1.2 mm Weldable wires aluminium 1.0 - 1.2 mm Brazable wires 0.8 – 1.0 mm Mains voltage 3 x 400 V Material Steel/stainless steel/aluminium Material thickness steel 0.8 – 10 mm Material thickn. alum. (welding only) 2 - 6 mm Set wire diameter 0.8 mm / 1.0 mm brazing wire Order number (PG12) 203.3300.0 Scope of delivery: Unit with remote-control torch ML 2400 PowerMaster, 3 m; MIG brazing torch set with combination carbon-teflon liner; ground cable 35 mm≈ long; pressure reducer with volume and contents manometer, adaptor for basket coils K300; mains cable 4 m with CEE 16-plug, fitted gas hose, operating manual.
56
Totally digital – the whole process. Arc control, ignition control, gas management system, wire burn-back without electrode sticking, wire speed control. Built-in diagnostics. Tacking, continuous, spot or interval.
No more experimenting with step switches. The welding unit gives the correct settings. Fully automatic correct welding and brazing. Digastep electronics control the process. Perfectly adjusted power stages result in a new quality of work. You don’t need to pay for a pulse-arc unit in order to experience simple welding. Innovation award 2001 of the German Federal Ministry of Research and Development.
Just 4 settings for perfect welding and brazing. •Material • wire diameter • gas • thickness of material. Ready. Everything else is adjusted by the M3030 Automotive. The best parameters are applied. Stored in a data base – with the knowledge of the best welders. By setting to the expert mode, specialists can always intervene in the system. But actually there is no reason why they should.
The new Power-Master-Torch. Integrated remote con trol and display, wire speed control, power and tiptronic can all be controlled at the torch. This would normally be an expensive extra feature.
Job memory. The Tiptronic. 100 work values can be saved and activated with a switch at the torch. Complete sets of procedures. Manufacturer’s guidelines. All stored – time-saving .
Digital display for voltage and current. Voltage and current values will be prescribed by future repair guidelines. All integrated ready for action.
Active Induction System (AIS). Ignition without spatter, brazing and welding with a constant arc even in the lower power range. No arc breaks or spatter. AIS automatically controls the induction coil under all conditions. This is our secret. If compared to a car, it would be the perfect adjustment of the suspension in a fraction of a second.
Undisturbed wire feed due to precise 4-roll drive system.
So inexpensive. How is that possible? Just € 2,930.We don’t believe that your job is to build a steel bridge across the River Nile, so the M 3030 is not equipped to perform such a task. Neither do we believe that you require a new pulse-arc unit for your new tasks. In our opinion, and from our experience, you need the M 3030 Automotive. It would be easy to recommend one of our more expensive welding machines. But we don’t, it is a matter of trust. Everything complete. Unit, powerMaster torch with 3 metre hose set, pressure reducer, ground cable.
57
Accessories M 3030 automotive Autoprotect X 10+11 , protection level DIN 10. Converts to DIN 11. MIG-MAG /Elect rode welding. Order no. 550.5311.0 (PG12) Autoprotect Flex 9-13 Protection level DIN 9 up to 13. Electrode/ MIG-MAG/TIG. Dark/light switching. Sensor web. Order no. 550.5312.0 (PG12) Autoprotect Multiflex 5-13 Protection level DIN 5 up to 13. Electrode/ MIG-MAG/TIG. Daylight filter, sensitivity regulator. Goes on where normal helmets give up the ghost. Order no. 550.5313.0 (PG12)
Lorch separating spray 400 ml Forms a thin protective film in the gas nozzle to protect against sintering of hot weld splashes. Order no. 551.9000.0 (PG2)
Special pliers MIG-MAG 4 functions. Cutting the welding wire. Cleaning the shielding gas nozzle. Pulling off the gas nozzle. Releasing the contact tip. Order no. 551.9070.0 (PG12)
MIG-MAG protective gloves Made of high-grade, durable leather. With wear-resistant seam. What a real welder’s glove should look like.
Feed rolls The feed rolls used in the wire feed unit have to be adapted in line with the wire you are welding. The feed rolls supplied for the M 3030 allow two different diameters to be processed. Fitted as standard with 0.8/1.0 mm aluminium feed rolls for processing brazing wires. The dual drive system always requires 2 feed rolls.
Feed roll for steel- and stainless steel wires (MIG-MAG) Wire diameter 0.6/0.8 mm, order no. 620.8940.0 (PG14) Wire diameter 0.8/1.0 mm, order no. 620.8709.0 (PG14) Wire diameter 1.0/1.2 mm, order no. 620.8941.0 (PG14) Feed roll for aluminium and brazing wires Wire diameter 0.8/1.0 mm, order no . 620.8708.0 (PG14) Wire diameter 1.0/1.2 mm, order no. 620.8953.0 (PG14)
CuSi3 wire for galvanised sheet 0.8 mm, small spool D200, 5 kg, order no. 590.1008.1 (PG 12) 0.8 mm, basket coil K300, 15 kg, order no. 590.1008.3 (PG 12) 1.0 mm, small spool D200, 5 kg, order no. 590.1010.1 (PG12) 1.0 mm, basket coil K300, 15 kg, order no. 590.1010.3 (PG12) CuAl8 wire for stainless steel 0.8 mm, small spool D200, 5 kg, order no. 590.1108.1 (PG 12) 0.8 mm, basket coil K300, 15 kg, Best. Nr 590.1108.3 (PG 12) 1.0 mm, small spool D200, 5 kg, order no. 590.1110.1 (PG12) 1.0 mm, basket coil K300, 15 kg, order no. 590.1110.3 (PG12)
Order no. 535.8210.0 (PG12)
Wire brush, 3 rows of bristles, Order no. 550.5210.0 (PG12) Wire brush VA, 3 rows of bristles, Order no. 550.5211.0 (PG12)
Ground cables with ground clamp and plug Steady, reliable current transmission is imperative to a neat tidy job. Defective or worn ground cables really do have to be replaced. 35mm2, 4m, plug 13mm, Order no. 551.0130.0
58
Adaptor for small spools This adaptor is required when 200 mm diameter spools are used. It serves as a spacer and guarantees reliable wire insertion. Order no. 620.9650.0 (PG 12)
Adaptor for basket coils K 300 The basket coil adaptor K 300 is required when using basket coils in the wire roll holder Order no. 551.9020.0 (PG12)
PowerMaster torch. Regulate power and speed by remote control in the torch itself.
MIG brazing torch set, 0.6-1.0 mm, also for stainless steel . Contents: Special combination carbon-teflon liner with flange-mounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. The set can be used for torches up to 5 m in length. Please order the matching contact tips and aluminium feed rolls separately. Order no. 551.2015.0 (PG2) Spare torch necks to fit: ML 1500 PowerMaster, order no.535.8400.1 (PG02) ML 2400 PowerMaster, order no.535.8400.3 (PG02)
Torch ML 1500 PowerMaster for M 3030 automotive Specifically for car body work. Compact, handy design. Max. current load 200 A. When used for MIG brazing, brazing torch set order no. 551.2015.0 is additionally required. For higher outputs, use torch ML 2400 PM. ML 1500 PM, 3 m, order no. 503.1501.3 (PG02)
Liners for ML 1500 PM, ML 2400 PM Liner for steel wire 0.6 - 0.9 mm, colour code blue For 3 m torch, (PG02), order no. 535.8300.1 For 4 m torch, (PG02), order no. 535.8300.2 Liner for steel wire 1.0 - 1.2 mm, colour code red For 3 m torch, (PG02), order no. 535.8300.3 For 4 m torch, (PG02), order no. 535.8300.4 For 5 m torch, (PG02), order no. 535.8300.5
Contact tips for torch, ML 1500 PM, PG2 Design Torch ML 2400 PowerMaster for M 3030 automotive Universal torch to cover the entire performance range. When used for MIG brazing, brazing torch set order no. 551.2015.0 is additionally required. ML 2400 PM, 3 m, order no. 503.2401.3 (PG02) ML 2400 PM, 4 m, order no. 503.2401.4 (PG02) ML 2400 PM, 5 m, order no. 503.2401.5 (PG02)
Pack
Order no.
0.6 mm M6
5
535.8101.1
0.8 mm M6
5
535.8101.2
1.0 mm M6
5
535.8101.3
1.0 mm M6
5
535.8101.5
1.2 mm M6
5
535.8101.6
For aluminium wire
Contact tips for torch, ML 2400 PM, PG2 0.6 mm M6
5
535.8106.1
0.8 mm M6
5
535.8106.2
1.0 mm M6
5
535.8106.3
1.2 mm M6
5
535.8106.4
1.0 mm M6
5
535.8106.5
1.2 mm M6
5
535.8106.6
For aluminium wire
Holding springs for gas nozzles, PG2 For ML 1500 PM
10
535.8100.9
Contact tip holders, PG2 Conversion kit aluminium 1.0 - 1.2 mm Contents: Special combination teflon liner with flangemounted brass spiral to extend the current transition zone in the torch neck, O-ring, collet and brass support pipe. The set can be used for torches up to 4 m in length. To pre vent wire damage, we recommend using 1.2 mm wire with a 3 m torch. Please order the matching contact tips and aluminium feed rolls s eparately. Order no. 551.2014.0 (PG2)
For ML 2400 PM
2
535.8120.4
2
535.8120.3
Gas diffuser, PG2 For ML 2400 PM
Gas nozzles, plug-in, for torch ML 1500 PM, PG2 Tapered gas nozzle
3
535.8100.1
Cylindrical gas nozzle
3
535.8100.2
Spot gas nozzle
3
535.8100.3
Gas nozzles, plug-in, for torch ML 2400 PM, PG2 Tapered gas nozzle
3
535.8120.1
Cylindrical gas nozzle
3
535.8120.2
59
A promi is a pro The rating plate. The bearer of truth. Or the last chance to bend the truth a little ??
Watch out! A high current rating is good. But is the relevant standardised working voltage right? It is only the current and voltage together which determine the necessary melting rate. Don’t be fooled by illusory current values.
You would imagine that this type of rating plate has to present the bare facts. The truth. We believe that the truth is what you get from Auenwald. Because we pledge and guarantee not to deceive anyone. We know manufacturers who do. Even on the rating plate. So we send our development engineers for 34 days a year to sit on committees and advisory panels at leading electrical engineering industry associations such as the DKE and the ZVEI, as well as the DIN standardisation agency, to help safeguard your interests.
The S mark Only units complying with regulations for welding in environments subject to high levels of electrical risk may bear this mark. High levels of electrical risk occur, for instance, when the welder is forced to make contact with electrically live parts. Workplaces in which the clearance from surrounding electrically conductive parts is less than two metres also qualify as at high electrical risk. The same applies to wet or damp workplaces in which the electrical resistance of work clothing or human skin can be reduced.
60
The protection class IP Protection classes according to type of housing (IP Code) are regulated by European standard EN 60529. Welding current sources must comply with protection class IP 21S as a minimum requirement. Always remember: Welding current sources which have to be used outdoors must comply with at least protection class IP 23. Anyone offering assembly units protected to IP 21 should be treated with suspicion.
se made ise kept The standards EN 60974-1 for Europe, VDE 0544 Part 1 for Germany. They contain the same thing, and are applicable for all welding current sources used for arc welding. Duty cycle, mechanical and electrical safety, type and piece testing etc. are all laid down in these standards. Why doesn’t everyone stick to them?
The duty cycle This is real test of honesty. In a MIG-MAG welding unit with a 60% duty cycle at 220 A this means: Welding current 220 A. The standardised welding voltage is 25V. The ambient temperature is set at 40 0C. The measurement period is always 10 minutes. 60% means 6 minutes of welding, 4 minutes break. Hours, days, weeks. So be wary of statements like ...200 A at 25 0C ambient temperature or ...60% duty cycle at intervals of 5 minutes, which are clearly in contravention of the standard.
Anyone who cheats is disqualified. We guarantee the accuracy of the values we specify. If you ever find your unit fails to live up to this claim, return it to us. We will give you your money back. No matter how old it is. Lorch, Auenwald, 2006 61
There are n that give “mo they The duty cycle (DC). No unnecessary compulsory breaks please. Mains voltage cannot be converted into welding voltage without losses. These are related to the internal resistance of the conductor. In Auenwald we use copper and nothing else for this construction. Many other use aluminium
The inverter. Where honesty is the best policy.
Technically speaking, inverter units do not
for cost reasons. The consequence is that the
A new type of welder the inverter has arisen
have a lot in common with welding transform-
unit heats up faster. And what happens? Your
from of the development of power electronics.
ers. They are complicated devices with a low
machine has to cool down and switches itself
The mains current is firstly converted into a
weight and compact design, but with excellent
off. The more often this happens, the worse it
direct current by diodes and then electronical-
welding properties. This technology is very
is for the service life of the machine.
ly "chopped" before being "smoothed". This is
expensive and entails a great deal of develop-
The relationship between the welding time
the only way to achieve a high transmission
ment work. Something that many manufactur-
and cooling phase is called the duty cycle.
frequency. The consequence: a smaller and
ers dread and therefore buy in from "else-
The standard EN 60974-1 is applicable when it
lighter transformer. Sounds simple, but it
where" abroad. After assembly they stick their
comes to determining the duty cycle of profes-
involves very complicated electronics.
own trademark, and in some cases "Made in
sional units. (The standard EN 50060 applies
Germany", on the device and Bob's your
for devices for limited use and hobby purpos-
uncle. Good ? Without their own experience,
es.) The duty cycle is determined within a
at the mercy of quality and know-how from
cycle period of 10 minutes (100%) A duty cycle
"elsewhere". Let's assume you need a spare
of 60% thus means that the welding time is 6
part after a few years. Just remember, we
minutes (60%) and the cooling time 4 minutes
build our own inverters an d know why.
(40%).
A question of trust.
62
ot many things re” back than receive. Amperes! Doesn’t mean a lot on its own.
Mains fuses.
ous welding accessories. The duty cycle is
The engine of a VW Golf can be rebored so
Some have their limitations.
determined at a certain ambient temperature.
that it shoots along at 250 kp/h. The ques-
Let's assume you want to weld, working with
Until recently this was 25°C, i.e. a tempera-
tion is, how would it handle? Hopefully it
a 230 V (lighting) power supply. But the
ture corresponding to average use in central
would still run straight ahead. A similar situ-
mains fuse keeps blowing. Tiresome. Or you
Europe. This has now been raised to 40°C. In
ation applies for welding devices when it
are working with a long extension lead and
Standard data can be used to compare vari-
some cases, during the transitional phase, this comes to amperes (horse power). These tell
you simply don't have enough power for
led to inaccurate comparisons. Which is why
you how much current is flowing in the arc.
welding! We would like to explain brief ly
we specify values at both 25°C and 40°C for
That's all. But welding, properties, ignition,
what exactly happens here. The energy need-
most of our welding accessories. You have the
inductor combination, no-load voltage, work-
ed in the arc or melt has to come directly
right information, and can compare for your-
ing voltage, optimum penetration and much
from the mains supply. We have developed
self. In principle, the higher the duty cycle,
more also have to be taken into account.
SPM (SinePowerManagement) specially for
the fewer the unavoidable breaks.
this. Our rivals have already read the most important features in our patent. However we are still keeping some "industrial secrets". These are securely under lock and key in our safe in Auenwald.
Only when all these aspects are optimised do you end up with a useful unit. This is expressed in what are commonly called welding properties. These are responsible for the welding speed, seam appearance and volume of spatter. However, you can still see people spending hours grinding off weld spatter. Over the years you lose more than just good money. But it's a well known fact that performance has its price – though with us this does not have to be unnecessarily high.
63
Plasma cutting The Lorch inverter plasma cutting units. Z 70 and Z 110. 4 times hotter than the sun itself. Incredible speed, durability, mobility. Fact is: Units in this power class usually weigh around 100kg. These get either weight lifted in the workshop like stone age monoliths or transported on site with a crane, if there happens to be one. This is history. Two newly developed plasma-cutting-inverter are playing this easy (to-carry) part in the market now. They cut bolt upright, circular, around angles, forward, to the left and to the right, all electrical conductive metals. Steel, stainless steel, aluminium, brass, copper. Sheet steel or pipes/tubes, container or steel beams: coated or laminated surfaces, even piled up sheets: usable with steel, container and construction work, air condition technology, on site. For cutting, preparation of welding seams, joint planing, hole pricking. And should you ever forget the combination of your safe, with a Lorch inverter plasma cutting unit you will be able to get your hands on your millions again in just seconds. Due to the infinitely variable adjustment of cutting and power intensity, both thick and thin materials can be accomplished with a neat cutting edge. Microprocessor controlled plasma logic enables the cutting of hole sheets and grates without interruption. Plasma-cutting is quite simple: you need the plasma cutting unit and compressed air. The produced plasma arc develops a temperature of up to 24.000°C. Four times more than the surface of the sun. The aerate pushes the liquid material out of the joint. The concentrated energy input enables highest cutting speeds. The fast energy input means: minor heat, minor distortion and exact cutting edges – even on thin metal sheets. A plasma cutting unit which generates its current using an inverter offers obvious benefits over a unit equipped with a conventional transformer. Substantially lower energy consumption for one. And we all know the cost of electricity. Soft-start ignition also places minimum stress on the cutting electrodes. A far longer service life and clearly improved cutting quality. Benefits you can start enjoying as soon as you like.
5064
65 51
Inverter plasma cutting unit Z 70, including torch 30 kg high-end durable technology, 70 Ampere
Inverter plasma cutting unit Z 110, including torch 31 kg go down to 42 mm depth, 110 Ampere
The technology: Primary Inverter-Powerpack. Minimal energy consumption. Controlled pilot arc for reliable ignition. Infinitely variable adjustment offers a cutting result ideally adapted to the material thickness, resulting in neat, precise cutting edges and optimised work speeds. Microprocessor controlled logic: high-frequency ignition and pilot arc for no-contact ignition. Soft switching for minimum strain on nozzles, digital display of cutting current and compressed air. Air flow control, air test function for convenient pressure adjustment. Automatic cool air post-flow noticeably increases the durability of the wearing parts. Digital security switching, display for all important status information. On-demand cooling with stand-by-switching: less power use, noise and contamination. Combined plasma torch. Cutting with spacer: precise and exact cuts, long service life, high cutting speed. Contact cutting with touch-down torch when working under cramped conditions. The torch is easily exchangeable due to the central mounting system. Interface for automatic solutions
Z 70 Method Plasma cutting Setting range cutting current inf. variable 22-70 A Cutting current at 100% DC (40°C) 50 A Duty cycle at max. current (40°C) 60 % (70 A) Mains voltage 400 V Mains fusing 16 A tr. Measurements appr. (LxWxH) 650x260x470 mm Weight 30 kg Air consumption 170 l/min Air pressure 5.5-7 bar Max. separating/quality cut with steel 22 / 17 mm Max. separating/quality cut with aluminium 17 / 12 mm Max. separating/quality cut with stainless steel 18 / 14 mm Order no. 321.0007.0 (PG 12)
Z 110 Plasma cutting 25-110 A 60 A 35 % (110 A) 400 V 32 A tr. 650x260x470 mm 31.5 kg 200 l/min 5.5-7 bar 37 / 32 mm 27 / 22 mm 30 / 24 mm Order no. 321.0011.0 (PG 12)
Scope of delivery: Unit complete with 6m torch type LCT 80 for model Z 70 or type LCT 150 for model Z 110. Ground cable 25mm≈; air pressure nozzle f itting, pressure reducer with filter for compressed air, mains cable 4 m with CEE 16 plug at model Z 70 or CEE 32 plug at model Z 110. Operating manual. Incl. wearing part set for the cutting torch.
Circle cutting attachment 2 pivot rods 250 mm + 400 mm, 3 pivot points, torch trolley. For torch LCT 80 Order no. 535.4015.0 (PG 14) For torch LCT 150 Order no. 560.0045.0 (PG 14)
66
Workshop trolley Straighten up out of that crouch position. This is the ergonomically optimum position for the equipment. For fast, pleasant working. The base makes a perfect resting surface. Order no. 570.3001.0 (PG 12)
Torches and wearing parts for the Z.
Complete torch LCT 80 Plasma cutting torch with central connection and 6 m long hose set. With original equipment set: 1 cutting electrode, 2 cutting nozzles, 5 spacer spr ings, 1 flowmeter. Order no. 511.9507.0, PG 2
Complete torch LCT 150 Plasma cutting torch with central connection and 6 m long hose set. With original equipment set: 1 cutting electrode, 2 cutting nozzles, 5 spacer s prings, 1 flowmeter. Order no. 511.9515.0, PG 2
10 15
10
25
20
30
30
45
40
25
20
30 45
30 40 50
50
50
58 100
55 110
130
60
70
80
90
Plasma cutting torch LCT 80, PG 2 Pos. Order no. Pack Name 10* 535.8503.0 2 Diffusor 20* 535.8503.1 5 Cutting electrode, short 30* 535.8503.2 2 Gas diffuser 40 535.8503.3 5 Cutting nozzle 1.0 < 50A 40 535.8503.4 5 Cutting nozzle 1.1 40-60A 40* 535.8503.5 5 Cutting nozzle 1.2 50-80A 50* 535.8503.6 1 Protective cap18.70 60* 535.8503.7 10 Spacer spring standard cut 4-point seating, 70 535.8503.8 1 Spacer nozzle vertical cut/template seating, 80 535.8503.9 1 Spacer nozzle 2-point oblique cut/mitre 90 535.8504.0 1 Torch trolley (PG14) Long design and for contact cutting 15 535.8504.2 2 Diffusor, long 25 535.8504.3 5 Cutting electrode, long 45 535.8504.4 5 Cutting nozzle, long 1.2 130 535.8504.5 2 Contact nozzle, long
* = Original equipment Cutting quality and safety during cutting depend on the quality of the torch. Experimentation is not an option here.
130
60
70
80
90
140
120
150
Plasma cutting torch LCT 150, PG 2 Pos. Order no. Pack Name 10* 535.8500.0 2 Diffusor 20* 535.8500.1 5 Cutting electrode short 30* 535.8500.2 2 Gas diffuser 40 535.8500.3 5 Cutting nozzle 1.4 50-80A 40* 535.8500.4 5 Cutting nozzle 1.6, 70-120A 40 535.8500.5 5 Cutting nozzle 1.8, 100-150A 40 535.8500.6 5 Cutting nozzle 3.0 gouging 50* 535.8500.7 1 Protective cap cylindrical 60* 535.8500.8 10 Spacer spring standard cut seating, vertical 70 535.8500.9 1 Spacer nozzle 4-point cut/template seating, oblique/mitred cut 80 535.8501.0 1 Spacer nozzle 2-point 90 535.8501.1 1 Torch trolley (PG14) 58 535.8501.2 1 Tapered prot. cap Pos. 140+150 100 535.8501.3 1 Adaptor ring 110 535.8501.4 5 Cylindrical nozzle guard ring 120 535.8501.5 5 Tapered nozzle guard ring Contact cut, cylindrical, 140 535.8501.6 1 Spacer nozzle vertical and mitre Contact cut round, 150 535.8501.7 1 Spacer nozzle vertical and mitre Long design and for contact cutting 25 535.8502.0 5 Cutting electrode, long 45 535.8502.1 5 Cutting nozzle, long 1.4 50-80A 45 535.8502.2 5 Cutting nozzle, long 1.7 70-120A 45 535.8502.3 5 Cutting nozzle, long 1.9 100-150A 55 535.8502.4 1 Protective cap 130 535.8502.5 2 Contact nozzle, long 67
Lorch AUTOprotects What the eye doesn’t see, the hand cannot reach.
We don’t manufacture this helmet ourselves and it was not bor n in Auenwald. It doesn’t even come from Ger many, because we could not find anything like it at home. Nevertheless it convinced us and we can thoroughly recommend it in the interests of your work and your health. We believe it offers the best view for positioning the torch welding rod. Its immediate darkening on ignition means an almost linear conversion at the speed of light. This automatic protection against temporary blinding is also a perfect, sturdy face protection against radiation, sparks and spatters. Energy is supplied by solar power. Always ready to use. Goodbye batteries. The appealing design of the helmet does n othing to compromise optimum ear protection against UV radiation. A headband design with facility for a wide range of different adjustments helps optimise wearing comfort .
68
Autoprotect X 10+11 Fixed protective level DIN 10. Can be con verted for fixed protective level DIN 11 using the supplied spare lens. Reasonably priced, tough autoprotect helmet for MIGMAG and electrode welding. Not s uitable for TIG welding. Solar cells mean the helmet is always ready for service without the need for a battery change. Order no. 550.5311.0 (PG12)
Autoprotect Flex 9-13 With adjustable protective level from DIN 9 to 13, providing reliable protection and an optimum view for electrode, MIG-MAG and TIG welding. Convenient adjustment from outside. The light-dark switching time can be set as required, e.g. to protect eyes against weld afterglow. The detachable sensor bar allows you to eliminate the influence of the ambient light and also ensure reliable darkening in all welding positions. Solar cells, without battery. Order no. 550.5312.0 (PG12)
Torch and welding rod, ideally positioned.
Order no. 550.5320.0 550.5320.2 550.5320.4 535.8700.0 535.8700.2 535.8700.4 535.8700.6 535.8700.8 535.8701.0 535.8701.2 535.8701.4 535.8701.6 535.8701.7 535.8701.8 535.8701.9
Autoprotect Multiflex 5-13 Highlight with adjustable protective level DIN 5 to 13. Electrode, MIG-MAG and TIG. Sensors and daylight filters detect the arc, and the sensitivity regulator controls response in every welding situation. Wherever “normal” helmets give up the ghost - low welding current, fast arc changes, welding around corners with concealed arc, reflective surfaces - you can rely on the Autoprotect Multiflex to stay safely darkened. Adjustable delay time opening to prevent dazzle by weld glow. Grinding mode – clear vision for grinding. Solar cells, without battery. Order no. 550.5313.0 (PG12)
Ignition: Instantaeneous darkening, light/dark switching time 0.001 of a second.
Name (helmets and parts PG 12) Helmet shell cmpl. with headband X10+11 Helmet shell cmpl. with headband Flex 9-13 Helmet shell cmpl. with headband Multiflex 5-13 Spare lenses, scratchproof X10+11 / pack of 10 Spare lenses, scratchproof Flex 9-13 / pack of 5 Spare lenses, scratchproof Multiflex / pack of 5 Spare lenses, internal / pack of 5 (all types) Headband cmpl. including sweatband Spare cartridge for X 10+11 Spare cartridge for Flex 9-13 Spare cartridge for Multiflex 5-13 Leather head and neck protector (all types) Leather chest protector (all types) Sweat band cotton / pack of 2 Helmet adaptor for work safety helmets (all types)
69
Welder’s a Welding accessories Professional welding equipment with highly flexible welding cable, electrode holder and ground clamp Protective shield EN 166 Welding glasses DIN 4646/4647 Wire brush and slag hammer
Welding cable extensions with cable coupler and cable plug
Design
Order no.(PG14)
25 mm , 3 m long, plug 9 mm
551.0016.3
25 mm2, 3 m long, plug 13mm
551.0025.3
35 mm2, 5 m long, plug 13mm
551.0035.5
50 mm , 5 m long, plug 13mm
551.0050.5
95 mm , 5 m long, plug 13mm
551.0095.5
2
25 mm2, , cable: 4 m electrode, 3 m ground, plug 9 Order no. 550.5506.0 (PG14)
2 2
25 mm2, , cable: 4 m electrode, 3 m ground, plug 13 Order no. 550.5503.0 (PG14)
Electrode holder
35 mm2, , 2 x 4 m, plug 13 Order no. 550.5504.0 (PG14) 50 mm2, , 2 x 4 m, plug 13 Order no. 550.5505.0 (PG14)
Design
Order no.(PG12)
Electrode holder 200 A
550.0050.0
Electrode holder 300 A
550.0051.0
Electrode holder 600 A
550.0052.0
Electrode welding cable with electrode holder and plug ground clamp
Design
Order no. (PG14)
25mm2, 4 m long, plug 9 mm
551.0210.0
25mm2, 4 m long, plug 13 mm
551.0220.0
35mm , 4 m long, plug 13 mm
551.0230.0
50 mm , 4 m long, plug 13 mm
551.0240.0
70 mm , 4 m long, plug 13 mm
551.0250.0
2
2 2
Design Quick earth plug 200 A, M 6 Quick earth plug 400A,M10 Quick earth plug 600A,M10
Welding cable plug Design
665.7310.0
Cable plug 35-50 mm 2, plug 13
665.7320.0
Cable plug 50-70 mm 2, plug 13
665.7330.0
Cable plug 70-95 mm , plug 13
665.7340.0
2
Design
Order no.(PG14)
25mm2, 4 m long, plug 9 mm
551.0110.0
25mm , 4 m long, plug 13mm
551.0120.0
35mm2, 4 m long, plug 13mm
551.0130.0
50mm2, 4 m long, plug 13mm
551.0140.0
70mm2, 4 m long,plug13mm
551.0150.0
2
70
Order no.(PG12
Cable plug 10-25 mm , plug 9 2
Ground cables with ground clamp and plug
Order no.(PG12) 550.0102.0 550.0103.0 550.0104.0
Welding cable couplers Cable coupler 10-25 mm 2, for plug 9 mm Cable coupler 35-50 mm 2, for plug 13 mm Cable coupler 50-70 mm 2, for plug 13 mm
Cable coupler 70-95 mm 2, for plug 13 mm
665.7210.0 665.7220.0 665.7230.0 665.7240.0
ccessories Special pliers MIG-MAG 4 functions in a single tool. Cutting the welding wire. Cleaning splashes off the shielding gas nozzle. Pulling off the gas nozzle. Releasing the contact tip. For torch ML 1500, ML 2500, Order no. 551.9070.0 (PG12) For torch ML 3600, MW 5500, Order no. 551.9071.0 (PG12)
MIG-MAG protective gloves Made of high-grade, durable leather. With wear-resistant seam. What a real welder’s glove should look like.
Order no. 535.8210.0 (PG12)
Protective shield
Manual mask EN 166, PE black Order no. 550.5120.0 (PG12)
Welding glasses 10 spare glasses, 90 x110 mm, clear Order no. 535.8200.1(PG12) 5 welder’s protective glasses DIN EN 166/169, 90 x 110 mm, protective level 9 Order no. 535.8200.2 (PG12) 5 welder’s protective glasses DIN EN 166/169, 90 x 110 mm, protective level 10 Order no. 535.8200.3 (PG12) 5 welder’s protective glasses DIN EN 166/169, 90 x 110 mm, protective level 11 Order no. 535.8200.4 (PG12)
High-grade TIG gloves Supple leather for an optimum feel. Lightweight. Once you have welded in these, you won’t want to take them off. Size M Order no. 535.8220.0 (PG 12) Size L Order no. 535.8220.1 (PG 12)
Pressure reducer Argon/mixed gas CO2
Order no. 570.9203.0 (PG14)
Slag hammer All steel, 350 g, order no. 550.5200.0 (PG12)
Wire brush, 3 rows of bristles, Order no. 550.5210.0 (PG12) Wire brush, VA, 3 rows of bristles, Order no. 550.5211.0 (PG12)
71
Electrode and TIG welding Model Welding
Setting range electrode 230 V Setting range electrode 400 V Weldable electrodes Setting range TIG 230 V Setting range TIG 400 V Setting No-load voltage Welding current at 100% DC (25/40)°C Welding current at 60% DC (25/40)°C Duty cycle at max. current (25/40)°C
A/V A/V dia. mm A/V A/V Steps V A A %
Mains (table values valid for:)
Mains voltage Mains frequency Mains fusing 230V / 400V (time-lag/C) Input power S1 (100 %) Input power S1 (at max I2) Mains current input (100 %) Mains current input (at max I2) Power factor (max I2) Power supply cable Mains plug (230/400V)
V Hz A kVA kVA A A cos phi mm◊
H140
H150
H180c
H180t
5-140A / 20.2-25.6V up to 3.25 inf. variable max. 85 - / 80 - / 110 - / 30 Electrode 230 50 / 60 16 2.90 5.60 12.4 24.2 0.99 3x1.5 shock-proof
5-150A / 20.2-26.0V up to 4.0 5-150A / 10.2-16.0V inf. variable max. 85 - / 115 - / 135 - / 40 Electrode 230 50 / 60 16 4.30 6.10 18.6 26.6 0.99 3x2.5 shock-proof
5-150A / 20.2-26.0V up to 4.0 5-180A / 10.2-17.2V inf. variable max. 85 - / 130 - / 150 - / 30 TIG 230 50 / 60 16 3.30 5.10 14.2 22.3 0.99 3x2.5 shock-proof
5-150A / 20.2-26.0V up to 4.0 5-180A / 10.2-17.2V inf. variable max. 85 - / 130 - / 150 - / 30 TIG 230 50 / 60 16 3.30 5.10 14.2 22.3 0.99 3x2.5 shock-proof
23 F F
