INTRODUCTIONMIGATRONIC welding equipment has a good reputation - and we know how important it isto live up to the standards we have set ourselves.The welding machine you have purchased is the result of MIGATRONIC'S years ofexperience in the field of welding machine manufacture. This experience, combined withcorrect operation and maintenance of your machine, provides a guarantee of excellentperformance in the years ahead.Thank you for buying a MIGATRONIC machine.

INSTRUCTION MANUAL

BDH 320/400/550

Version E 50173005

EC DECLARATION OF CONFORMITY

MIGATRONIC A/SAggersundvej 339690 FjerritslevDenmark

hereby declare that our machines as statedbelow

Type: BDH 320/400/550as of: week 49 1995, step 4

conform to directives 73/23/EEC and89/336/EEC.

European Standards: EN60974-1EN50199

Issued in Fjerritslev on 4th December 1995.

Peter RoedManaging director

Valid from 9715

CONTENTS

Description of functions...................... 5

Initial operation................................... 7

Control switches............................... 10

Connection for MIG/MAG welding ... 12

Connection for TIG welding ............. 13

Connection for MMA welding........... 13

Technical data.................................. 14

Maintenance .................................... 16

Detection of errors -

MIG/MAG welding............................ 17

Personal safety ................................ 18

IMPORTANT SAFETY INSTRUCTIONS

The safety instructions contained in the PERSONALSAFETY section of this manual should be read andobserved when installing and operating the machine.

This instruction manual and the accompanying instructionsfor use must be accessible at all times to staff engaged inthe installation, operation and maintenance of the machine.

Full understanding of this manual requires a skilled welder'sknowledge of welding and of the risks involved.

5

DESCRIPTION OF FUNCTIONSThe BDH range consists of 6 basic models.

BDH 320 TIG: Welding machine for TIG andMMA electrode welding.

BDH 320 MIG/MAG: Welding machine forMIG/MAG and MMA electrode welding.Available as either a compact model withintegrate wire feed unit, or as a combi mo-del, this being a compact model fitted withan additional separate wire feed unit.

BDH 320/400/550 MIG/MAG STB: Weldingmachines for MMA electrode welding, andMIG/MAG welding with a separate wire feedunit.

BDH 320/400/550 TRIPLE: Welding machi-nes for TIG, MIG/MAG and MMA electrodewelding.

The BDH is an inverter-based machine. Theadvantages of this design are as follows:

- programmable welding properties andimproved welding characteristics,

- a reduction in power loss,- increased duty cycle,- reduced weight and size

The inverter, like all other components in themachines, is controlled by a centralmicroprocessor, which makes it possible toachieve advanced welding control combinedwith straightforward operation and ease ofuse.

The design of the BDH is based to a largeextent on modules. This modular construc-tion has two advantages, i.e. (1) greatflexibility, enabling users to design themachine that they need to meet their speci-fic requirements, and (2) ease of service,since repairs can be carried out simply byreplacing defective modules.

The most important modules are describedin brief below.

InverterAs mentioned above, the BDH is an in-verter-based machine. That is, the powersource (power module) is constructed inaccordance with the switch-mode principle.The BDH power module switches at 100kHz, which makes it the fastest inverter onthe market today. The principle involved isillustrated in the block diagram below.

6

DESCRIPTION OF FUNCTIONSThe electronic boxThe microprocessor is placed in the elec-tronic box, and forms part of a regulatingloop in which measurements of weldingcurrent and voltage are carried out. Thecurrent and voltage references are genera-ted to the inverter based on these mea-surements, with a frequency of 10 kHz.

In addition to the regulation of weldingcurrent and welding voltage, the micro-processor deals with all control and collec-tion of data from modules in the weldingmachine. It also provides communicationwith the user via the front of the electronicbox and operation using either the torch orremote control.

Wire feedA wire feed system is used in MIG/MAGwelding, and can be situated either on theleft-hand side (seen from the front) of thepower source (COMPACT), or in a separatewire feed unit (STB and TRIPLE), or bothplaces (COMBI). The wire feed unit can befitted with either two or four-wheel drive.Four-wheel drive is recommended for manywelding tasks - not least when aluminium orfluxcored wire is used.

It is also important to use wire feed rolls thatfit the dimensions of the wire, and that theliners used in the torch hose are of thecorrect diameter and material to suit thetype of welding wire in question ( See para-graph: Fitting of welding wire).

HF-moduleThe HF module consists of an HF box and acoil. The HF module is used to initiate thearc during TIG welding.

Water moduleThe water module consists of a water tank,a water cooler, a water pump, a filter, andflow control. The flow control system in-dicates a water cooling error if the coolingwater flow is either insufficient or absentaltogether.

7

INITIAL OPERATIONMains connectionThe machine must be connected to a three-phase alternating current (AC) supply (50 or60 Hz) with a mains voltage between 380and 415 V. The order of the phases is notimportant. The earth wire is yellow/green.Fuse type: According to typeplate. Use themains switch to switch on the machine (pos.1).

-markingThis machine meets the demands made formachines which are to operate in environ-ments with an increased hazard of electricshock.

In certain types of welding jobs there is anincreased hazard of getting an electricshock, e.g. in environments where thewelder has to work in a crouched positionand is therefore in contact with the work-piece, in places which are partially or totallysurrounded by conductive parts, and in wet,damp or hot places.

When welding under such conditions theremust be a person nearby who can renderhelp in case of an emergency and he mustbe able to quickly cut off the current.

Protection classThe machine is designed for indoor ope-ration as it meets the demands of protectionclass IP21.

It must be ensured that the air intake andoutlet are not blocked.

Electromagnetic emissions and theradiation of electromagnetic disturban-cesIn conformity with the ElectromagneticCompatibility (EMC) Directive within theEuropean Union this high-quality weldingmachine for industrial and professional useis designed, built and tested in accordancewith the European Standard EN50199 onradiation and incident radiation of electro-magnetic disturbances, the purpose of thisstandard being to prevent the occurrence ofsituations, where the machine is disturbedor is itself the source of disturbance in otherelectrical equipment or appliances.

The responsibility of the userA trouble-free performance without dis-turbances or disruption caused by elec-tromagnetic emissions, does, however,require that certain measures are takenwhen installing and using the welding e-quipment.

Thus it is the responsibility of the user toensure that the operation of this machinedoes not occasion disturbances of theabove mentioned nature.

Before installing and operating the weldingmachine, an assessment of the surroundingarea is therefore required and this assess-ment is best performed by the specialistinstalling the welding machine.

Assessment of areaThe following shall be taken into account:

1. Supply cables for other equipment,control cables, signalling and telepho-ne cables in the vicinity of the weldingmachine.

2. Radio or television transmitters andreceivers.

3. Computers and any control equipment.

S

8

4. Critical safety equipment, e.g. electri-cally or electronically controlled guardsor protective systems around process e-quipment.

5. The medical health circumstances ofpeople in the area, e.g. the use of pace-makers, hearing aids etc.

6. Equipment used for calibration andmeasurement.

7. The immunity to disturbance or disrup-tion of other equipment in the environ-ment which may be disturbed and whichtherefore may require special protectionmeasures.

8. The time of day that welding or otheractivities are to be carried out.

The size of the surrounding area to beconsidered will depend on the structure ofthe building and those other activities thatare to take place in the environment. Speci-al circumstances may require an extensionof this area.

Use in domestic establishmentsThis welding machine is normally expectedto be used in industrial situations and areas,and if used in a domestic establishment thehazard of disturbing other electric appli-ances is increased and it may be necessaryto take special and additional precautions inorder to prevent problems of emission.

Methods of reducing electromagnetic emis-sions

- The welding cables should be kept asshort as possible.

- The welding cables should be positio-ned with the negative and the positivecables close together.

- The welding cables should be runningat or close to floor level.

- Mains cables and other cables, e.g.telephone, computer, and signallingcables, should not be carried or placedparallel and close to each other, e.g.not in the same cable tray or box.

- Separately-insulated mains supplycables for sensitive electronic equip-ment, e.g. computers.

- Selective screening of cables may beconsidered under special circumstan-ces.

- Screening of the entire welding instal-lation may be considered under specialcircumstances and for special applica-tions.

How to connect the gasThe gas hose, which is connected to therear of the machine, should be connected toa gas supply with a flow setting of 8-20l/min, depending on the welding operation inuse. TRIPLE and COMBI types are fittedwith two gas hoses.

The left-hand gas hose is for use inside themachine, and the right-hand gas hoseshould be connected to the separate wirefeed unit. A gas cylinder or fittings for twinbottles can be fitted to the rear of the ma-chine.

9

How to connect the separate wire feedunitConnect the separate wire feed unit to themachine using an intermediary cable whichcontains cables and hoses for weldingpositive (pos. 2), control signals (pos. 5),gas (pos. 6), and cooling water (pos. 7 and8), if a water module is incorporated in themachine.

FRONT REAR

10

MIG Compact + CombiBDH 320

TRIPLEBDH 320/400/550

MIG STBBDH 320/400/550

TIGBDH 320

11

FRONT PANEL

1. Mains switch

2. Positive outlet

3. Negative outlet

4. TIG negative outlet

5. Multiple plug for connection of separate wire feed unit

6. Quick-release coupling for gas to separate wire feed unit

7. Quick-release coupling for cooling water to separate wire feed unit

8. Quick-release coupling for cooling water returned for separate wire feed unit

9. Euroconnector coupling for MIG hose and torch assembly

10. Connection for push-pull hose and torch assembly

11. Quick-release coupling for cooling water returned to MIG torch

12. Quick-release coupling for cooling water to MIG torch

13. Quick-release coupling for gas to TIG torch

14. Six-pin outlet to TIG torch

15. Cooling water returned from TIG torch

16. Cooling water to TIG torch

12

CONNECTION FOR MIG/MAG WELDINGWelding hose connection:The welding hose is mounted in the centralconnection (pos. 9), and the nut is tightenedmanually. Connect the return cable to thewelding negative (pos. 3). If a water modulehas been fitted in the machine, the twowater hoses should also be fitted: RED forquick water connection (pos. 11), and BLUEfor quick water connection (pos. 12). Forpush-pull hoses and torches fit the controlcable plug to the eight-pin multiple plug(pos. 10) next to the central connection.

Fitting the welding wire:Turn the tension spring aside and tip up thelever (fig. 1). Check that the wire feed roll,wire guide liner, and capillary tube corre-spond to the wire diameter. Capillary tubeand wire guide liner as below are recom-mended (fig. 3).

fig. 1

Unscrew the contact tip if it is fitted to thewelding torch. Insert the wire reel and feedthe wire through the teflon inlet nozzle, thewire feed, and then on into the capillarytube. Tip down the lever, turn the tensionspring into place. Press the key on themotor control box, and the wire will runthrough the hose. When the wire is throughthe hose, the contact tip is fitted. The pres-sure of the thumbscrew is adjusted to allowthe wire feed roll just to slide on the wirewhen this is stopped at the contact tip.

With the push-pull hose: Remember toleave open the liner unit of the torch whenfitting the wire (fig. 2).

fig. 2

0,8 0,8 white 1,2 0,8

1,0 1,0 blue 1,5 1,0

1,2 1,2 red 2,0 1,2

1,6 1,6 red 2,0 1,6

2,0 2,0 yellow 2,7 2,0

2,4 2,4 yellow 2,7 2,4

fig. 3

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CONNECTION FORTIG WELDING

Connect the TIG hose cable to the weldingnegative (pos. 3) in TIG models or to thespecial TIG negative outlet (pos. 4) inTRIPLE models.

Connect the return cable to welding positive(pos. 2).

Connect the gas hose for the TIG torch tothe quick-release coupling (pos. 13).

If the machine has built-in water module,and if a watercooled hose is used, connectthe cooling water to the blue coupling (pos.16) and the return cooling water to the redcoupling (pos. 15).

Connect the control cable for the TIG torchto the six-pin plug (pos. 14).

CONNECTION FORMMA WELDING

Connect the electrode holder to the positiveoutlet (pos. 2) and the return cable to thenegative outlet (pos. 3).

Select polarity in accordance with the in-structions of your electrode supplier.

OPERATIONThe operation of the control box is describ-ed in the separate instructions for opera-tions, which are enclosed.

14

TECHNICAL DATA

Power source BDH 320 BDH 400 BDH 550

Mains voltage-standard version-version withchange-over switch

Fuse

EfficiencyNo-load effect

Permitted load:- 35% duty cycle- 40% duty cycle- 60% duty cycle- 100% duty cycle

Open circuit voltageMMA,MIG/MAG,TIG

Current range

Internal wire feed unit(Compact/Combi)

Water module:- Cooling effect- Cooling capacity

Application classProtection classNorm

Dimensions withoutwire feed unitWeight incl.water module

3x400 V ±10%3x230 V 1±0%

3x400/440/500 V ±10%

According to typeplateon the machine

0.85100 W

320 A / 32.8 V-

260 A / 30.4 V220 A / 28.8 V

80 V

5 - 320 A

as KT14

850 W7 l

SIP 21

EN60974EN50199

67x46x80 cm

110 kg

3x400 V ±10%3x230 V ±10%

3x400/440/500 V±10%

According to typeplateon the machine

0.85100 W

400 A / 36.0 V-

355 A / 34.2 V310 A / 32.4 V

80 V

5 - 400 A

not available

1600 W4 l

SIP 21

EN60974EN50199

67x46x80 cm

115 kg

3x400 V ±10%3x230 V ±10%

3x400/440/500 V±10%

According to typeplateon the machine

0.85100 W

-550 A / 42.0 V500 A / 40.0 V400 A / 36.0 V

80 V

5 - 550 A

not available

1600 W4 l

SIP 21

EN60974EN50199

67x46x80 cm

135 kg

Wire feed unit, type KT12/KT14 KT22/KT24 KT22/KT24

Operatingsupply voltageEffect, 1-2 pcs.

Wire dimensionWire reel capacityWire speed

DimensionsWeight

24 Vac

105 W

0.8 - 3.2 mm5 - 15 kg

1 - 24 m/min.

70x40x21 cm22 kg

24 Vac

105 W

0.8 - 3.2 mm5 - 15 - 30 kg1 - 24 m/min.

61x22,5x28 cm14.6 kg

24 Vac

105 W

0.8 - 3.2 mm5 - 15 - 30 kg1 - 24 m/min.

61x22,5x28 cm14.6 kg

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TECHNICAL DATA

Control:

Arc power

Hot-start

Antifreeze

Pilot arc

Starting current

Stop current

Slope-up

Slope-down

Gas pre-flow

Gas post-flow

Spot welding time

Arc adjust (inductance)

Burn-back

Pulse time

Pulse frequency

Basic current

Process library

Sequence possibilities

MMA

MMA

MMA

TIG

TIG

TIG

TIG

MIG/MAG, TIG

MIG/MAG, TIG

MIG/MAG, TIG

MIG/MAG, TIG

MIG/MAG

MIG/MAG

A:B:

A:B:

MIG/MAG

0 - 100 %

0 - 100 %

on/off

5 - 50 A **

0 - 100 % min. 5A

0 - 100 % min. 5A

0 - 10 secs

0 - 99.9 secs

0 - 10 secs

0 - 60 secs

0.1 - 99.9 secs

0 - 100 %

0.05 - 0.5 secs

0.1 - 99.9 msecs0.01 - 9.99 secs *

1 - 999 Hz0.1 - 50 Hz *

0 - 100% min. 5 A

27 synergic processes

1 - 4

*Only valid for TIG box and TRIPLE box

**TRIPLE box: 5 A

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MAINTENANCEHowever good materials have been usedand no matter how carefully the fitting hasbeen done, an advanced product as aMIGATRONIC MIG/MAG welding machinerequires your contribution if it is to operateperfectly for years. The following itemsdemand special attention:

Wire feed unitThis unit is to be cleaned with clean, drycompressed air and checked regularly atthe wire feed roll and the contact tips, as it isof great importance for a satisfactorywelding result and a minimum of wear andtear that the wire passes through the wiredrive system without deformation of the wireor the wire feed roll.

The contact tips should be checked fre-quently and changed if the copper plating ofthe wire is damaged on its way through thetips. Copper dust may totally hinder freepassage through the wire liner.

A weekly check and cleaning of the tip andthe wire feed roll is recommended.

Welding hoseGreat care should be taken to ensure thetorch hose assembly is properly protected. Itshould not be pulled over sharp edges, andheavy machines should not run over it as itmay damage the wire lines.

The hose assembly should be dismantledevery week and blown out with clean, drycompressed air. The torch should be dis-connected during this process.

Welding torchThere are many parts in the welding torchthat have to be cleaned regularly. The mainones are the contact tips and the gasshroud.

During the welding process, these parts arebombarded with spatter that sticks in theshroud. This may disturb the shielding gasflowing from spatter the gas shroud down tothe molten pool, and should be removedregularly. Add MIG-SPRAY to loosen this.

During the cleaning process, the gas shroudshould be removed. Do not attempt to cleanthe shroud by beating the torch.

Power sourceThe power source should be checked andcleaned at least once a year by trainedservice staff.

Water moduleIf the level of coolant in the tank falls so lowthat the machine is disconnected (errorinformation in the control box display), thenextra coolant should be added, using thefilling nozzle on the rear of the machine.(Waterlevel should be checked regularlyand the filter should be cleaned).

To ensure reliable operation, always useMigatronic coolant (order no. 99290400).

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Detection of errors in MIG/MAG welding

Errors Origin

Uneven wire feed 1. The inlet guide and the groove in the wireroll are not in line.

2. The wire reel is running too tight on thespindle. Sometimes the wire is wronglyreeled so it "crosses".

3. The inlet guide or the contact tip is worn,dirty or maybe blocked.

4. The welding wire is dirty, corroded or of poorquality.

5. There is too little pressure on the counter-roll.

Too much spatter 1. Too high a wire speed in relation to the wel-ding job in hand.

2. The contact tip is worn.

The weld has a coked or brittleappearance. When spot weldinga characteristic top appears.

1. The gas nozzle is blocked.

2. The system contains leaks so that at-mospheric air is sucked in and mixed withthe shielding gas due to the injector effect.

The wire sticks in the contact tipseveral times and runs slowly.

1. Can be caused by a deformation of the wirein the liner. Cut off the wire at the wire rolland pull the deformed wire out of the liner.Fit a new wire roll and check the pressure onthe drive roll.

2. The contact tip is worn.

18

PERSONAL SAFETY

Light and heat emissionA welding arc emits radiation which isdamaging to the human eye. Even short-term exposure to this radiation can causelasting damage. Protect your eyes frompowerful radiation by infra-red, visible andalso ultra-violet light by installing suitableradiation protection glass in your weldinghelmet.

Your skin can also be damaged by weldingradiation. Radiation can cause seriousburns. Protect your skin by wearing a weld-ing helmet, working clothing covering allexposed parts, and gloves.

During welding, warn other people in thevicinity of the danger of radiation andsparks. If possible, place a screen betweenthe place of work and the surroundings.

The heat emitted from the arc and poolcrater - as well as the sparks emitted duringwelding - represent a fire hazard.Consequently, welding should never becarried out near combustible materials.Working clothing must not be made of sub-stances which are easily combustible, andshould have no folds or open pockets intowhich sparks can fall. Wear a fire resistantapron if necessary.

Welding fumesThe smoke and gases emitted during wel-ding are damaging to the health. Conse-quently, the inhalation of welding smoke andgases should be avoided by taking suitablepreventive measures (e.g. local airextraction, ventilation, or supply of fresh airto welding helmet).

ElectricityAvoid contact with all live components.

The voltages used in welding are not suffi-cient to represent a danger in themselves.However, if damp clothing is worn, or ifworking in damp conditions, electric shockscan be caused, representing an indirectsource of danger.

Considerable electric shocks can be causedby HF high voltage ignition during TIGwelding in particular, and may lead to minorburns beneath the skin.

Consequently, all contact with live compo-nents should be avoided as far as possible.

Always use dry, leather welding gloves andwear dry working clothing and shoes. Keepcables, torches, and the welding machineitself dry at all times.

Make sure that the welding machine's earthconnection is properly and safely earthed.

Do not open the machine to expose livecomponents. Maintenance and servicewhich require access to live componentsinside the machine must be carried out byan authorized electrician.