book of welding 2007

Lorch Schweisstechnik GmbH D-71547 Auenwald Postfach 1160 T. +49 (0)7191.503.0 F. +49

(0)7191.503.199 [email protected]

www.lorch.biz

The Bookof

Welding

For the workshop and building site2006 and 2007

913.

1000

.1/2

You are holding

the book of welding

Presented by

your dealer

Electrode weldingCL 0

Electrode weldingTIG weldingH Page 10ISI5 CL Page 28

TIG weldingHT Page 17HandyTig Page 20

MIG-MAG weldingA Page 34M 2000 Page 44M 3000 Page 48

MIG brazingA CuSi Page 34M 3030 Page 55

Plasma cuttingZ Page 64

Helmets/accessoriesPage 68

Data Page 72

Our day-to-day work is all about putting the best possible instrument in yourhands. As you see, we share a joint ambition: Top quality workmanship

7

Full 3-yearwarranty

Which adds up to 8,760 working hours. 365 days a year - timesthree. This is the period for which we guarantee the functional char-

acteristics of our products. We are confident that nothing can gowrong with a system or a unit bearing the name Lorch. But in theunlikely event that a fault should occur, we undertake to repair it

and to shoulder the cost. As you will appreciate, this does not applyto wearing parts.

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 registeronline 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.

The law currently requires a fixed warranty on material and produc-tion defects in commercially used products of 1 year. Given our out-look 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 pur-

chase, but another 2 years on top. But please do tell us where yourequipment is being used and who you are.

3 times longer than the statutory requirement.

8

Process kn

Basic knowledge: Electrode welding

The electric arc burns between the material

and melting electrode. The electrode simulta-

neously supplies the filler metal. The stick

electrode is clamped in an electrode holder

and positioned by the welder. Stick elec-

trodes are generally coated. The coating also

melts and protects the molten pool and arc

against outside air by releasing gases and

slag.

The slag is removed after the molten pool

cools.

Devices marked with an (S) can also be used

under higher electrical risks. Inverter

welders have very good welding properties

and are thus also suitable for special elec-

trodes. Nearly all weldable materials can be

welded with stick electrodes, e.g. structural

steel, boiler steel, steel tubes, cast steel,

stainless steel, hard facing steels, etc.

Electrode welding is simple and safe. The

compact devices are easy to handle and

transport. Since no gas is needed, welding

can be performed outdoors, even in wind.

Electrode weld machines are used in all

lines of business, from industry through to

craftsmen.

Basic knowledge: MIG-MAG welding

With the MIG-MAG method (MIG = Metal

Inert Gas/MAG = Metal Active Gas) the elec-

tric arc burns between the melting, automat-

ically supplied welding rod (= electrode) and

the material. A separately supplied gas pro-

tects the arc and welding zone against out-

side air. The shielding gas and welding rod

must be matched to the base material.

Weldable materials include:

Aluminium, aluminium alloys

Method: MIG

Wire electrode: matched to the material to be

welded

Welding shielding gas: Ar, He or mixtures

General structural, boiler, tubular steel

Method: MAG

Wire electrode: SG 1-3

Shielding gas: mixed gas (Ar/CO2) or CO2Stainless steel, high alloy steel

Method: MAG

Wire electrode: matched to the material to be

welded

Shielding gas: Mixed gases (e.g. Ar/CO2 or

Ar/CO2/O2)

MIG/MAG welding is the most popular weld-

ing method nowadays on account of its enor-

mous advantages. The high welding speed,

minimum reworking and low distortion

ensure high efficiency. The great weld seam

strength, excellent thin-sheet properties and

simple and safe handling with steel, alumini-

um and stainless steel make the method uni-

versally acceptable.

Electrode welding MIG-MAG welding

Shielding gas nozzle

Contact tip

Electrode

Shielding gas

Arc

Melt zone

Base material

Basic knowledge: MIG brazing

Called MSG (Metal Shielding Gas) brazing

according to international standards - is a

hard-soldering procedure. The electrical arc

burns between the melting, continuously

applied brazing wire electrode and the work-

piece. The added shielding gas protects the

arc and the liquid brazing metal against the

influences of the ambient air. The applica-

tion is as simple as MIG-MAG welding. MIG

brazing offers clear advantages for the join-

ing of galvanised sheets compared to MIG-

MAG welding. Only a fractional zinc melting

loss occurs in the immediate brazing zone

(zinc melts at 419°C, evaporates at 906°C)

due to the low melting temperatures of the

brazing wire (approximately 1000°C). The

soldering seam features a high corrosion

resistance and enables easier surface treat-

ment. The soldering wires consist of copper

based alloy with a component of, for exam-

ple, silicon or aluminium. There is minimal

distortion, even on very thin sheets, due to

the low heat input. Coated (galvanised, phos-

phated, aluminised) and uncoated steel

sheets, stainless steel and steel/stainless

steel compounds (black/white compounds)

may be soldered. Soldering seams provide

excellent assembly strength. Shielding gas:

pure argon or argon with minor additives.

Galvanised thin sheet is used in the automo-

tive engineering and building industries, in

air conditioning technology, household appli-

ances and in the furniture industry. MIG

brazing is ideal for these applications.

MIG brazing

Shielding gas nozzle

Contact tip

Soldering electrode

Shielding gas

Arc

Solderingmaterial

Base material

Stick electrode

Coating

Core wire

Gas/Slag

Arc

Melt zone

Base material

9

nowledge

Basic knowledge: TIG welding

With the TIG method (TIG = Tungsten Inert

Gas) the electric arc burns between the non-

melting tungsten electrode and the workpiece.

The arc is very intense and can be very easily

controlled. A separately supplied argon shield-

ing gas protects the arc and the welding zone

from the atmosphere. Filler metals can be fed

by hand or with a special cold wire feed if

necessary. Steel, stainless steel, copper, titani-

um, etc. are welded with direct current. The

electrode is connected to the negative pole

and ground to a point.

Aluminium, magnesium and their alloys

should only be welded with alternating cur-

rent to break open their oxide skin. The elec-

trode is blunt.

During welding it can assume a round or

crowned shape. With modern inverter power

sources, a pointed tungsten electrode can also

be used. The advantages of TIG welding: its

easy handling and good control over the arc

enable very comfortable and clean working.

The low oxidisation of the workpiece, small

welding zone, omission of fluxing agents and

non-spattering arc ensure clean, precise

seams with no slag inclusions and no rework-

ing.

TIG welding

Gas nozzle

Tungsten electrode

Shielding gas

Arc

Melt zone

Base material

Basic knowledge: Plasma cutting

When plasma cutting, the electrical arc

burns between the non-melting electrode

and workpiece. The arc is additionally con-

stricted by a nozzle and applied compressed

air, which increases the intensity and stabili-

ty considerably. Due to this constriction a

highly heated gas with high energy content

originates in the torch, whose electrical ener-

gy is converted into heat. This ionised gas

which transfuses the arc onto the workpiece

is called plasma.

Cuttable materials:

By using the plasma-cutting procedure mate-

rials such as steel, stainless steel, alumini-

um, copper, cast, brass, etc. can be cut.

The special advantages:

Due to the energy density of the plasma arc

a high cutting speed is obtained. The cuts

are steep, flash- and distortion free and of

high economic efficiency.

Trouble-free handling and use of simple com-

pressed air as a cutting gas offer unlimited

possibilities. Used in the steel industry,

installation, container construction and

many other areas.

Plasma

ElectrodeCutting gasCooling gasPlasma nozzle

Plasma arc

Base material

Basic knowledge: E = mc2

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Einstein

10

Drop it? Yes you can.Standards specify that an inverter welding device must be capable of withstanding a free drop of 25cm. But let’s be honest: If a unit falls off a table or out of your hand it will be travelling a good 80 cmbefore it hits the ground. An H from Lorch is capable of surviving this degree of drop and will still goon 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 pro-duct is already looking a little clearer. Otherwise what’s to stop that clumsy apprentice sneaking adamaged 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 againstfailure due to high or low temperatures, dust, chips and moisture.

Consistent HighTecAn 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 controllerIt takes a perfect microprocessor to regulate the arc correctly. All the better - and all the finer andmore controlled the droplet transfer and the spatter formation. Its adaptive behaviour compensatesfor handling errors and helps stabilise the welding result. Even with difficult electrodes and in awk-ward confined spaces. It is a Bestseller or a Flop.

We present: the better inverter.

Do please measure the duty cycle at 40°CThe 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 technologyMinimal power loss - high efficiency. Standby function for minimal energy consumption during breaks.

Overvoltage and undervoltage protectionSafeguards 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 sensorsReduce the ingress of dirt bycontrolling the fan only as and when required.

The H

11

www.werkzeugforum.de/testsieger.htm

Electrode

CRASHPROOF

TESTWinner

A Lorch Handy H150

will survive any drop from a height of 80 cm.

Extremely good welding properties.

Maximum welding current, 100% DC.

Best duty cycle. The only system in which

all specified values were correct.

Awarded top marks (grade A) by

TIG

New: H140Super lightweight. High duty cycle of 30% at 140 A. Simple to operate.Automatic adaptive hot start for perfect ignition. Anti-Stick system prevents electrodesticking. Arc force regulation provides support for difficult electrodes. Durable assemblydesign, insensitive to knocks, safety due to protection class of IP 23. High mains voltagetolerance, 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)

Ideal for electrodes up to 3.25 mm. 140 A and an outstanding duty cycle.

H 140 assembly packAll neatly tucked inside. With everything you need for electrodewelding. H 140, with mains cable, shock-proof plug, transporta-tion belt, 3 m electrode - and ground cable 16 mm2, slag hammer,wire brush, protection shield EN 166, welding glasses DIN 4646-47. Complete in a sturdy case with handy compartments.Order no. 105.0141.1 (PG 12)

Model 2004 unit: 5.2 kg

12

Method Electrode welding

Electrode diameter 1.5-3,25 mm

Material electrode Steel/stainless steel

Recommended material thickness up to 8 mm

Welding range 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

New: H150High performance reserves. Duty cycle of 40% at 150 A. Simple to operate. Automaticadaptive hot start for perfect ignition. Anti-Stick system prevents electrodesticking. Arc force regulation provides support for difficult electrodes. Switchover toTIG welding with ContacTIG ignition for good TIG welding. Durable assemblydesign, insensitive to knocks, safety due to protection class of IP 23. High mains volt-age tolerance, troublefree with long extension leads and good generators. Bears the Slabel denoting suitability for use in confined spaces in atmospheres subject to higherelectrical 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)

Ideal for electrodes up to 4 mm. Higher powered with 150 A.Good for TIG welding.

H 150 TIG assembly packWith everything you need for TIG and electrode welding. An H 150, with mains cable, shock-proof plug, transportation belt, 3 m electrode - and ground cable 25 mm2, slag hammer, wirebrush, 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 con-tent manometer. All in a sturdy case with handy compartments.Order no. 105.0152.2 (PG 12)

13

H 150 assembly packEverything you need for electrode weldingon 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, weldingglasses DIN 4646-47.Complete in a sturdy case with handy compartments.Order no. 105.0151.1 (PG 12)

Electrode

TIG

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 1-4 mm / copper 1-3 mm

Welding range 5 – 150 A 5 – 150 A

Duty cycle at max. current (40°) 40 % 40 %

Current at 60 % DC (40°) 135 A 135 A

Mains voltage 230 V

Weight 5.2 kg

New: H180cEnough 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 settingson 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 flowprotects tungsten needle and welding seam from oxidation. 2 and 4 stroke logic for quick tacking and convenientseam welding. Automatic down-slope prevents quality impairing “end craters” at the end of the seam. Fast down-slopeusing 2nd torch key prevents fall-through of the seam in case of workpiece overheating. Durable assemblydesign, insensitive to knocks, safety due to protection class of IP 23. High mains voltage tolerance, troublefree with long exten-sion leads and good generators. Bears the S label denoting suitability for use in confined spaces in atmospheres subject to higherelectrical 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)

H 180c assembly packWith everything you need for electrodewelding on the move. An H 180c, with mains cable, shock-proofplug, transportation belt, 3 m electrode - and ground cable 25mm2, slag hammer, wire brush, protection shield EN 166, weld-ing glasses DIN 4646-47. Complete in a sturdy case with handycompartments. Order no. 105.0181.1 (PG 12)

H 180c TIG assembly packWith 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, wirebrush, protection shield EN 166, welding glasses DIN 4646-47.plus TIG set, comprising: TIG torch WLT 17K, 4 m; tungsten elec-trode, pressure reducer with volume and content manometer,plug-in gas hose. Complete in a sturdy case with handy compart-ments. Order no. 105.0182.2 (PG 12)

14

TIG

Method Electrode welding TIG welding


Weldable material Steel, stainless steel Steel, stainless steel/copper



Duty cycle at max. current (40°) 40 % / 150 A 30 % / 180 A

Current at 60 % DC (40°) 135 A 150 A

Mains voltage 230 V

Weight 5.7 kg

Electrode

New: H180tEverything 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. Longservice 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 weldingcurrent and process status. Operator prompting using illuminated symbols. Convenient TIGsequence: 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 toprotection class of IP 23. High mains voltage tolerance, troublefree with long extension leads and good generators. Bears the S labeldenoting suitability for use in confined spaces in atmospheres subject to higher electrical risk. The standby system reduces fannoise, soiling and energy consumption. Remote control facility.H 180t, with mains cable, shock-proof plug, transportation belt, order no. 105.0185.0 (PG 12)

H 180t TIG assembly packWith everything you need for TIG and electrode welding stowedaway neatly. The H 180t, mains cable with fitted shock-proof plug,operating manual. Additionally with 3 m electrode and groundcable 25 mm2, slag hammer, wire brush, protection shield EN166, welding glasses DIN 4646-47, plus TIG set, comprising: TIGtorch WLT 17K, 4 m; tungsten electrode, pressure reducer withvolume and content manometer, plug-in gas hose. Complete in asturdy case with handy compartments. Order no. 105.0187.2(PG 12)

15

TIG

Electrode

Method Electrode welding TIG welding with HF ignition


Weldable material Steel, stainless steel Steel, stainless steel/copper



Duty cycle at max. current (40°) 40 % / 150 A 30 % / 180 A

Current at 60 % DC (40°) 135 A 150 A

Mains voltage 230 V

Weight 6.5 kg

HighEnd. Enough power for electrodesup to 4 mm. Even better TIG weldingdue to no-contact HF ignition.

TIG wearing partsAccessories in detail

Equipment kits in case for TIG

Kit 1 for 1.6 mm - WLT 17/26, 3 collets and colletbodies, 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 colletbodies, 5 ceramic gas nozzles size 6;1 W electrodeOrder no. 551.3052.0 (PG2)

16

Assembly wire feeder for all H models, empty Sturdy assembly wire feeder to hold the unitand one set of welding equipment.Order no. 610.0806.0, (PG 12)

Autoprotect X 10+11, protection level DIN 10. Converts to DIN 11. MIG-MAG /Electrode welding.Order no. 550.5311.0 (PG12)

Autoprotect Flex 9-13Protection 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 reducerOrder no. 104.9002.0 (PG12)

H 180c and H 180t TIG equipment WLT17TIG 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 cableOrder no. 105.9002.0 (PG12)

Foot remote control FR 35with 5 m lead, switches welding current on and off, controls welding current intensityand down-slope.Order no. 570.1135.0 (PG14)

Accessories

Steel 1.0 1.0 10-60 4and 1.5 1.0-1.6 40-80 5st. steel 2.0 1.6 70-120 5

3.0 1.6-2.4 90-150 64.0 2.4 140-180 7

Copper 1.0 1.0 60-80 4and copper 1.5 1.6 100-150 5alloys 3.0 2.4 150-180 6

Material Mat. thick- Dia. mm Welding Sizeness, mm tungsten current, ceramic

electrode amperes gas nozzle

Ceramic gas nozzles for TIG torch WLV/WLT17/26To determine the correct size, see the explanationprovided above.Size Pack Order no.

4 5 pcs. PG2 535.8003.45 5 pcs. PG2 535.8003.56 5 pcs. PG2 535.8003.67 5 pcs. PG2 535.8003.7

Collets for TIG torch WLV/WLT17/26To determine the correct size, see the explanationprovided above.Size Pack Order no.

1.0 mm 5 pcs. PG2 535.8000.11.6 mm 5 pcs. PG2 535.8000.22.4 mm 5 pcs. PG2 535.8000.3

Collet body for TIG torch WLV/WLT17/26To determine the correct size, see the explanationprovided above.Size Pack Order no.


Tungsten electrode goldNew-style, lathanised, with excellent ignition properties.Environmentally friendly. 100% radiation free, 175 mm.Size Pack Order no.


Clamping cap WLV/WLT17/26 shortReplaces 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)

17

Electrode

TIGprofessionalTIG

18

Method TIG and electrode welding Electrode diameter TIG 1.0 – 3.2 mmWeldable material Steel, stainless steel/copper/aluminiumRecommended material thickness 1 - 8 mm/ 1 - 3 mm/1 - 8 mmElectrode diameter Electrode 1.5 – 4.0 mmWelding range 3 - 180 A, DC + ACAdjustment Infinitely variableDuty cycle at max. current (40°C) 35 %Welding current at 60% DC (40°C) 140AProtection class IP23Mains voltage 230 VWeight 13 kgScope of delivery: HT 180 AC/DC with mains cable, shock-proof plug, transportation belt.

TIG

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 func-

tion using the 2nd torch button helps prevent “fall-through”. The welding current is now convenientlycontrolled directly at the torch. Simply connect the UP/DOWN torch. The variable alternating currentfrequency 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.

TIG Inverter HT 180 AC/DC. With transportation belt. Order no. 250.0181.1 (PG12)Available from September 2006

The new HT 180 AC/DC.

Electrode

19

The new HT. More advantages.

Crash proofThe unit is sitting onthe workbench, someo-ne knocks it down.Broken. A working daywritten off. Units whichhave adequate protec-tion are not immediatelyrecognizable. The stan-dard stipulates 20 cm.Ever seen a 20 cm hightable? We protect the HTat 9 crash points. Whichis enough. After all, no-one wants to tote astrong box.

Design – for practicalpurposes only.Appearing with a LorchT under your arm sayssomething about yourprofessional attitude.Compact dimensions,recessed control panel.Logical functions andclearly arranged dis-plays. Nothing to detractfrom the effective, ergo-nomic styling.

Dust is death to wel-ding equipment. To some maybe – butnot ours.We consider this classictrick to shorten the ser-vice life of a weldingunit to be somewhatbelow the belt. Dustspells the end for thepower electronics. Insidecoating, an extra coolingchannel for the assem-blies and the visible topfilter are three answerswhich make for impro-ved durability.

Just one of many use-ful details. A dedicatedspace for the cable, inte-grated in the handle andclosed using Velcro tape.An end to cable spaghet-ti. And that irritatingcable waiting to trip youup just in front of yourfoot has now gone. Adetail – maybe. Butthese are just the pointswhich add up to turn agood unit into a greatone.

The trolley. It places thewelding unit at a safeand comfortable workingheight, while thosegenerous and highly sta-ble wheels make foroptimized transport. Order no. 570.3035.0(PG 12)

The maxi trolley foradditional 50l gascylinders.Order no. 570.3036.0(PG 12)

TIG equipment kit WLT 26 DDComplete equipment for TIG welding,comprising TIG torch WLT 26 DD, withdouble pushbutton. Ground cable 25mm2, 4m; Pressure reducer with volume and content manometer, gas hose 1.8 m.

SET WLT 26DD, 4 m longOrder no. 569.2610.4, (PG 12)SET WLT 26DD, 8 m longOrder no. 569.2610.8, (PG 12)

Complete equipment kit for TIG weldingwith remote control function at thetorch. Comprising TIG torch WLT 26 UD,with double push button und up-downfunction 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.

SET WLT 26 UD, 4 m longOrder no. 569.2620.4, (PG 12)SET WLT 26 UD, 8 m longOrder no. 569.2620.8, (PG 12)

More accesoires on page 23

Hand remote control HR 30For remote adjustment of the welding current. Complete with 5 m lead.Order no. 570.1031.0 (PG14)

Extension cable setFor 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)

Foot remote control FR 35with 5 m lead, switches welding current onand off, controls welding current intensityand downslope by means of a foot pedal.Order no. 570.1135.0(PG14)

Assembly case HTSturdy transport case. Protects the unit and equipment.Order no. 610.0808.0 (PG12)

20

No one packs so much power smaller.The HANDY-TIG.

TIG

HANDY-TIG 210 AC/DC

21

HANDY-TIG 210 DC

The truth weighs just 8000 g, is 35 cm long, 13.8 cm wide and 32 cm high. That's all you need to know. Don't be fooled by any-one. 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 life,

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 the 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

Method TIG welding TIG weldingElectrode welding Electrode welding

Electrode diameter TIG 1.0-2.4 mm 1.0-3.2 mm

Weldable material Steel, stainless steel / copper Steel, st. steel / copper /alum

Recommended material thickness 1-6 mm / 1-3 mm 1-6 mm / 1-3 mm /1-5 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

Protection class IP23 IP23

Mains voltage 230 V 230 V

Weight 8.3 kg 11.1kg

Protection class IP23 IP23

Order number (PG12) 254.0210.0 254.1210.0

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

Programm-Anzeige. Und los geht’s.

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.

Carefully engineered functions for optimum convenience. Direct current welding with 2-stroke 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 igni-tion. Automatic preflow and postflow. Down-slope using second torch button as a standard fea-

ture (prevents fall-through of the molten pool.) Programmed end current down-slope with correc-tion 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 isunplugged. 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.

2. Simple programselection with the Lorchinching logic systemand LED display

3. Ignition current: infinitely variable from 7 to 180amperes.

Program display. And off you go.

4. End current down-slope:Program controlledwith correction controller.

1. Welding current: Infinitely variablefrom 3 to180 amperes.

The operation panel, 1:1

Foot remote control FR 35with 5 m lead, switches welding current on and off, controls welding currentintensity and down-slope.Order no. 570.1135.0(PG14)

Hand remote control HR 30for remote adjustment of the welding current, complete with5 m lead.Order no. 570.1031.0 (PG14)

Extension cable set complete with cable plug and socket.For extending the hand remotecontrol lead. KSF 75, 7.5 m long, Order no. 570.9033.0 (PG14)KSF 150, 15 m long. Order no. 570.9036.0 (PG14)

Assembly case HANDY-TIG. Study transport case. Protects the unit and equipment, evenspace for the Autoprotecthelmet. Order no. 602.1227.0 (PG12)

22

Accessories for die HANDY-TIG

23

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 ina 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 99.5Filler metal for pure aluminium. The welding seam areamust be metallically bright. Suitable for base materials Al 99.5, Al 99. 50 rods, 2.0 mm, order no. 590.5120.4 (PG 12)

Aluminium AlSi 5Filler metal for aluminium silicon alloys and for joiningaluminium alloys of different types. The welding seamarea must be metallically bright. Suitable for base mate-rials AlMgSi 0.5, conditionally for AlMgSi 0.8 andAlMgSi 1 and for aluminium cast alloys up to 7 % Si.100 rods, 2.0 mm, order no. 590.5220.4 (PG 12)

Stainless steel 1.4576Filler metal for welding unstabilised and stabilised cor-rosion-proof Cr Ni-Mo steels for operating temperaturesup 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, 1.458350 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 jointsbetween 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)

Ground cables with ground clamp and plugSteady, reliable currenttransmission is imperative toa neat, tidy job. Defective orworn ground cables should be replaced in good time. The originalHANDY-TIG cable is available as a spare. 25 mm2, 4 m long, plug 13 mm, order no. 551.0120.0 (PG14)

Autoprotect helmets. Electronic protective helmets forwelders with high-speed darkening. Clear view for posi-tioning the torch and welding wire. Darkens immediatelyon 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)

Top-quality TIG gloveSupple 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 holder25 mm2, 4 m long, with electrodeholder and 13 mm connecting plug.Is required to weld electrodes. Order no. 551.0220.0 (PG 14)

Torch and wearing parts for HANDY-TIGThe 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% bybuying these counterfeit copies. But you can rest assured they are made of cheaper basic materials. Otherwise there would be noprofit margin for the plagiarists. After all, our spare parts are just as valuable and complex to produce as the system itself. Youwill pay for those cheaper spare parts by higher wear, more working time and substandard welding results. Those are the facts.

TIG wearing parts To ensure optimum welding results, electrode diameters,welding current and gas nozzle must all be adjusted in linewith the thickness. On the right is a table containing the relevant guideline values.

TIG torch for HT and HANDY-TIGTorch 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 HTTorch 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)

24

Ceramic gas nozzles for TIG torch WLV/WLT17/26To determine the correct size, see the explanationprovided above.Size Pack Order no.


Collets for TIG torch WLV/WLT 17/26To determine the correct size, see the explanationprovided above.Size Pack Order no.

1.0 mm 5 pcs. PG2 535.8000.1 1.6 mm 5 pcs. PG2 535.8000.2 2.4 mm 5 pcs. PG2 535.8000.33.2 mm 5 pcs. PG2 535.8000.4

Collet body for TIG torch WLV/WLT17/26To determine the correct size, see the explanationprovided above.Size Pack Order no.

1.0 mm 2 pcs. PG2 535.8001.11.6 mm 2 pcs. PG2 535.8001.22.4 mm 2 pcs. PG2 535.8001.33.2 mm 2 pcs. PG2 535.8001.4

Material Thickn.mm Dia. mm Ampere Gas nozzle


3.0 1.6-2.4 90-150 64.0-6.0 2.4-3.2 140-180 7

Copper and 1.0 1.0 60-80 4copper 1.5 1.6 100-150 5alloys 3.0 2.4 150-180 6Aluminium 1.0 1.0 10-60 4

1.5 1.6 40-80 52.0 1.6 70-120 53.0 2.4 90-150 64.0 3.2 140-180 75.0 3.2 170-180 7

Tungsten electrodes, goldNew-style, lathanised, with excellent ignition properties. Longservice life. Suitable for DC and AC. Environmentallyfriendly,100 % radiation free. Length: 175 mm. For match-ing diameters, see above table.

Diameter Pack Order no.1.0 mm 10 pcs. 535.8006.1 PG21.6 mm 10 pcs. 535.8006.2 PG22.4 mm 5 pcs. 535.8006.3 PG23.2 mm 5 pcs. 535.8006.4 PG2

Tungsten electrodes, greenPure tungsten, for welding aluminium materials with AC.Good arc shape, very stable arc. Not for DC. Length 175mm. For matching diameters, see above table.

Diameter Pack Order no.1.0 mm 10 pcs.. 535.8005.1 PG21.6 mm 10 pcs. 535.8005.2 PG22.4 mm 5 pcs. 535.8005.3 PG23.2 mm 5 pcs. 535.8005.4 PG2

Clamping cap WLV/WLT 17/26 short, for restrictedspace 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, for2.4 mm- WLT 17/26, 3 collets and collet bodies, 5 ceram. gas nozzles size 6, 1 T electrode Order no. 551.3052.0 (PG2)

Clear view of the grinding process.

All electrode sizes with diameters of 1 to 4mm can be ground. Electrodes which are as short as 15mm, or are badly eroded or damaged with spatter,

can be handled.

Grinding dust is removed by an integral filter unit, ensuring the health and safetyof the operator.

Diamond grinding wheels with 3longlasting grinding surfaces. Adjustedby means of a handle.

The grinding angle can be varied from 15° - 180°.Only 0.3mm of material surface is removed.

Precision grinding finish. Accurate electrode guidance.

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 mechanismOrder no. 810.8606.0(PG 12)

The Peak

25

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.

Order no. PGGrinding wheel dia. 40 mm 810.8601.0 12Electrode holder 810.8602.0 12Collet chuck dia. 1.0 mm 810.8603.0 12Collet chuck dia. 1.6 mm 810.8603.1 12Collet chuck dia. 2.0 mm 810.8603.2 12Collet chuck dia. 2.4 mm 810.8603.3 12Collet chuck dia. 3.2 mm 810.8603.4 12Collet chuck dia. 4.0 mm 810.8603.5 12Filter cassette 810.8604.0 12Viewing window 810.8608.0 12Disposable filter bag 810.8605.0 12

TIG-knowledge

26

A very intense and focused arc is producedduring TIG welding. The advantages are aminimum introduction of heat, narrowseam and welding without filler metals.Only the base material fuses with itself lea-ding to perfect quality visible welds. Verysmall currents can be set with good TIGinverters, thus enabling the welding ofvery thin materials.Industry and trade have been makingmoney with the advantages of TIG wel-ding for a long time.Whenever demands such as leakproof, safefor foods, visible, etc. are placed on a weldseam, irrespective of whether stainlesssteel or aluminium are used, TIG is thesolution. TIG machines used to be big andcumbersome. Moreover, their setting wascomplicated and their purchase price high.However, the increased use of stainlesssteel and aluminium means that metalwor-king companies are having to turn to TIGwelding – including on building sites.

TIG welding for you.Which is why we have developed ourHANDY inverters to spare you any pro-blems. Small, lightweight and handy.Therefore easy to use, because a lot of whatyou previously had to set has been integra-ted during their development as “artificialintelligence”. Each machine is designed for welding froma 230 V lighting mains. Since anythingwhich is good sells easily, we have consi-stently 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 canbe performed “outdoors” without any pro-blems. Nor do you have to mask off largeareas, spattering is a thing of the past.Everything is lighter, smaller and easier tohandle. Convincing advantages over the“heavyweight” rivals. You drastically redu-ce finishing work, because the look andquality 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. DCwelding is used for steel, stainless steeland copper, AC for aluminium and magne-sium. A further important difference is theignition method: you choose between non-contact HF ignition and contact ignition,also called lift-arc ignition. During contactignition the tungsten electrode is placed onthe workpiece - a low current flows, thesystem switches over to the welding cur-rent by raising the electrode slightly, thearc is ignited. The advantages of thismethod are a low purchase price and nointerference with other electronic devicesthrough HF. However, there is the risk thattungsten impurities will remain on theworkpiece, which can lead to corrosion.During HF (= High-frequency) ignition thetungsten electrode is kept at a distance. Short HF pulses ionise the air gap betweenelectrode and workpiece. The arc ignites.An absolutely professional ignition method.When all is said and done, anyone whodoes without TIG technology today is notdoing himself a favour, because TIG wel-ding has become simpler.

27

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 I3 as per DIN EN 43930 % He, rest Argon50 % He, rest Argon70 % He, rest Argon

Another handy tip for everyday TIG weldingA frequent mistake people make is incor-rect handling of the tungsten electrode.With direct current (DC) welding, the elec-trode must be ground to a point lengt-hways relative to the current flow direc-tion. Even grinding ridges should be polis-

hed away. Anyone omitting to do this willexperience magnetic faults leading to con-siderable ignition problems and an insta-ble light arc.For alternating current (AC) welding, up toa diameter of 1.6 m, electrodes do notrequire grinding, although for electrodesover this diameter, a chamfer is required,naturally also in the longitudinal direction.

This is the only way to ensure anarrow light arc and a neatseam which is not too wide.The Lorch Teg 4.0 tungstenelectrode grinding machine isthe ideal way to keep yourelectrodes in tip-top conditi-on. Guaranteed to eliminateignition problems and arcinstability. For details, turnback a page.

28

Anyone who needs to weld with 5 mm thick electrodes opts for the ISI.

Switchover facility from 230 V to 400 V.

Electrode

TIG

29

A milestone in the history of converter construction. The ISI 5 CL combines the “ideals” of electrode welding like no othermachine we make. This inverter miracle has maximum voltage reserves thanks to the generously dimensioned Power-Mos powermodule and high-speed arc control, combined with a complex ripple filter. This all adds up to a very stable DC arc, which in turnmeans better welding than many others! Every location and position. Not forgetting the 6 selectable current programs, an extra-ordinary thin sheet pulse from 0.8 mm and a patented power circuit. This is very unusual for an inverter, but unbelievably use-

ful: it allows you to switch from 230 to 400 V. A feature which knows no limits. Make it ISI – buy ISI.

ISI 5 CLThere 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)

Accessories

Accessories for TIG on page 41

Welding accessoriesSPA 35 mm2/ plug 13, professionalwelding equipment, 35mm≈ highlyflexible 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 hammerOrder no. 550.5504.0 (PG14)

Extension cable set complete with cable plug and socket.For extending the hand remotecontrol 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 30for remote adjustment of the welding current, complete with5 m lead.Order no. 570.1031.0 (PG14)

Transportation beltSimplifies transport on site. Complete set with fixings.Order no. 570.4100.0 (PG12)

What you need for TIG weldingTIG lift arc set WLV 26/3550,comprising TIG valve torchWLV 26, 4 m; tungsten electrode 2.4 mm, pressure reducer with volume and content manometer. Order no.104.9005.0 (PG12)

Method Electrode welding/TIG welding

Electrode diameter (electrode/TIG) 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) 3-200 A/3-220 A

Current at 60% duty cycle (25°/40°) 200A/170A

Setting stepless

Mains voltage 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, remote-

controllable. 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.

30

Revered as a legend among welding machines. The CL.

Electrode

Our classics. A blueprint for our rivals and equipment used by over 100,000 men on this continent. For business, workshop andbuilding 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 wrongwith the ergonomics and a fibreglass-reinforced polyester housing is indestructible, never rusts and is fully insulated. The hous-ing will never be “live” in the event of defects or if dropped or incorrectly connected on building sites. The CL today is as good asit ever was. As the transformer and inductor are of copper, the only way to achieve the right ignition and welding properties. Theworking point can be ideally set for both machines. This is guaranteed by 11 settings for the CL 4 P-F and an infinitely adjustablecontrol 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 alwayswithin reach and easy to read from a distance. The thermocontrol, an overload protection with warning display, provides addi-tional 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 just CL 5 P-F just

To match: Complete set of welding accessories.

SPA 25 mm2/ 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)

31

CL 4 P-F CL 5 P-F

Method Electrode welding Electrode welding


Material 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

Settings 11 Infinitely variable welding current settingin a single revolution

Mains voltage 230/400 V 230/400 V

Order no. (PG12) 106.5005.0 106.5007.0

Scope of delivery: Unit with mains cable with CEE-16 plug, mains adaptor 230 V/400 Vwith shock-proof plug, operating manual.

LabourWages and salaries account

for 76 cm of the overall costs

32

Important! Whof weld seam

Gas9 cm

Wire6 cm

Electricpower

4 cm

Unit5 cm is what your

welding unit costs.

Acquisition, depre-

ciation, interest.

33

h at does 1metre really cost?

This is something we should all give some

thought to. Compared to the costs of labour,

fuel and consumables, the purchase of a

new welding unit pales into insignificance.

But the tendency is to concentrate on the

price of the machine and forget what hap-

pens next. Particularly if we look at labour

costs, which can be pushed through the

roof by choosing the wrong, cheap welding

equipment. Think about it: At Lorch we

build welding machines designed to make

your work and your life easier. And for this

we charge you a whole 5 cm.

Realistically 76 cm working time

As a rule, a “talented welder” will put in a

good 1,907 hours a year. If he uses a less

talented welding unit which reduces his

work input by just 8%, that makes 152.56

hours lost. But if we assume an hourly

wage of 17.90 € an, that adds up to

2,730.80 € every year. And the fact that

this type of welding equipment is written

off on average over five years means the

whole deal will cost you 13,654.-- € on top.

Not to mention the effect on your nerves.

So perhaps now you are closer to under-

standing a typical Lorch precept: Better

good and sound than bad and unreliable.

34

One for all

MIG-MAG

TIG

Electrode

MIG-brazing

35

1.Select

MIG-MAG, TIG

electrode

3.Current and

voltage settingdigitally displayed

Precision wirespeed

adjustment

For TIGdown-slope

Digitallydisplayed

Infinitely variable MIG-MAG inductor for steel stainless steel aluminium

4- stroke

Spots

Interval

with TIGpulsing

Intervention inthe automatic

system for individual fine

tuning

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 roughtreatment. 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 lugginga 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 airusing gasless wire. Just like a normal wire spool. Forget scaling the scaffolding clutching a gas cylinder. These wires contain a specialpowder 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 thecorrosion protection. MIG brazing is a process which takes place only at 800°C. Minimal heat, negligible voltage, practically nodistortion. And the ACuSi is ideal for use on brazing robots too.

TIGPress once for

slower up-slope and down-slope,

perfect seam startno end craters

2.Select

diameter of welding wire

tungsten needle stick electrode

2- stroke

A 17000.8 wire MIG-MAG, 150 A TIG, electrode 4 mm.

230V. 19 kg on siteOrder no. 201.1700.0 (PG 12)

A 22001.0 wire MIG-MAG, 200 A TIG, electrode 5 mm.

230/400V. 20 kg on siteOrder no. 201.2200.0 (PG 12)

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.

36

The A offer TIG, MAG-MAG and electrode

A MIG-MAG without gas.These wires contain aspecial powder whichgenerates gas and slag. A simple resetting job.

A 1700 A 2200Welding range MIG-MAG infinitely variable 35 - 170 A 35 – 220 ADC at max. current (40°) 25 % / 170 A 15 % / 220 ACurrent at 60 % DC (40 °) 120 A 170 AMains voltage 230 V 230 V / 400 V 1 PhWeldable wires steel/aluminium 0.6-0.8 mm / 1.0 mm 0.6-1.0 mm / 1.0 mmMaterial MIG-MAG Steel / stainless steel / aluminiumRecommended material thickness steel / aluminium 0.8-5 mm / 2-3 mm 0.8–8 mm / 2-5 mmWelding range TIG/electrode 5–150/25-150A 5-200/25-200ADC at max. current (40°) TIG/electrode 35 %/30% 35 %/30 %Current at 60 % DC (40 °) TIG/electrode 130/120 A 170/170 AElectrode diameter TIG/electrode 1.0-2.4/1.5-3.25 mm 1.0-3.25 mm/1.5-5.0 mmWeldable material TIG/electrode Steel, stainless steel, with TIG also copperRecommended material thickness for TIG 1-4mm/copper 1-3 mm 1-6 mm/copper 1-4 mmRecommended material thickness for electrode up to 10 mm up to 12 mmWeight 19 kg 20 kg

A 1700 CuSi0.8 wire MIG-MAG, 150 A TIG, electrode 4 mm.

230 V. 19 kg on site.Order no. 201.1710.0 (PG 12)

A 2200 CuSi1,0 wire MIG-MAG, 220 A TIG, electrode 5 mm.

230/400 V on site.Order no. 201.2210.0 (PG12)

37

ACuSi

The A offer TIG, MIG-MAG, electrode and MIG-brazing

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.

A 1700 CuSi A 2200 CuSiWelding range MIG-MAG infinitely variable 35 - 170 A 35 – 220 ADC at max. current (40°) 25 % / 170 A 15 % / 220 ACurrent at 60 % DC (40 °) 120 A 170 AMains voltage 230 V 230 V / 400 V 1 PhWeldable wires steel/aluminium 0.6-0.8 mm / 1.0 mm 0.6-1.0 mm / 1.0 mmMaterial MIG-MAG Steel / stainless steel / aluminiumRecommended material thickness steel / aluminium 0.8-5 mm / 2-3 mm 0.8–8 mm / 2-5 mmWelding range TIG/electrode 5–150/25-150A 5-200/25-200ADC at max. current (40°) TIG/electrode 35 %/30% 35 %/30 %Current at 60 % DC (40 °) TIG/electrode 130/120 A 170/170 AElectrode diameter TIG/electrode 1.0-2.4/1.5-3.25 mm 1.0-3.25 mm/1.5-5.0 mmWeldable material TIG/electrode Steel, stainless steel, with TIG also copperRecommended material thickness for TIG 1-4mm/copper 1-3 mm 1-6 mm/copper 1-4 mmRecommended material thickness for electrode up to 10 mm up to 12 mmWeight 19 kg 20 kg

38

MIG-MAG accessories A 1700, A 2200 and CuSiConversion kit aluminium, 1.0 or 1.2 mm. 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. For torches up to 4 m. Order no. 551.2014.0 (PG2)

Conversion kit stainless steel, 0.6/0.8/1.0 mmCombination 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)

Liners ML 1500, ML 1500 PMLiners ML 2400, ML 2400 PM

Liner for steel wire 0.6 - 0.9 mm, colour code blueFor 3 m torch, (PG02), order no. 535.8300.1For 4 m torch, (PG02), order no. 535.8300.2

Liner for steel wire 1.0 - 1.2 mm, colour code redFor 3 m torch, (PG02), order no. 535.8300.3For 4 m torch, (PG02), order no. 535.8300.4

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 torchML 2400, 3 m long, order no. 503.2400.3 (PG2)ML 2400, 4 m long, order no. 503.2400.4 (PG2)


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)


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)


PowerMaster torch. Regulate power and speed byremote control in the torch itself.

Contact tips for torch, ML 1500 + ML 1500 PM, PG2Design Pack Order no.0.6 mm M6 5 535.8101.10.8 mm M6 5 535.8101.21.0 mm M6 5 535.8101.3For aluminium wire1.0 mm M6 5 535.8101.51.2 mm M6 5 535.8101.6Contact tips for torch, ML 2400 + 2400 PM, PG20.6 mm M6 5 535.8106.10.8 mm M6 5 535.8106.21.0 mm M6 5 535.8106.3For aluminium wire1.0 mm M6 5 535.8106.51.2 mm M6 5 535.8106.6Retaining springs for gas nozzles, PG2For ML 1500 + PM 10 535.8100.9Contact tip holders, PG2For ML 2400 + PM 2 535.8120.4Gas diffuser, PG2For ML 2400 + PM 2 535.8120.3Plug-in gas nozzles, for torch ML 1500 + PM, PG2Tapered gas nozzle 3 535.8100.1Cylindrical gas nozzle 3 535.8100.2Spot gas welding nozzle 3 535.8100.3Plug-in gas nozzles, for torch ML 2400 + PM, PG2Tapered gas nozzle 3 535.8120.1Cylindrical gas nozzle 3 535.8120.2

39

Torch original equipment kitContaining the different accessory kits - but packaged safelyand neatly in a sturdy plasticcase with handy compartmentsOrder no. 551.0490.1 (PG12)for ML 1500, justOrder no. 551.0490.3 (PG12)for ML 2400

Set of torch wearing parts for ML 2400Case containing the following mainwearing parts :3 tapered gas nozzles,10 contact tips 1.0 mm,Order no. 551.2524.0 (PG12)

Set of torch wearing parts for ML 1500Case containing the following mainwearing parts.3 tapered gas nozzles,10 contact tips 0.8 mm,10 retaining springs.Order no. 551.1508.0 (PG12)

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)

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)

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 gas0.9 mm dia. For low-alloyed sheet materials up to 15 mm.Small spool D 200, 4.5 kgOrder no. 590.0200.9 (PG 12)

High-grade brazing wires ACuSiCuSi3-wire for galvanised sheet0.8 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 (PG 12)1.0 mm, basket coil K300, 15 kg,order no. 590.1010.3 (PG 12)CuAl8 wire for stainless steel0.8 mm, small spool D200, 5 kg,order no. 590.1108.1 (PG 12)0.8 mm, basket coil K300, 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)

Original equipment kit for torch ML 1500, 3 mKit 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)

Original equipment kit for torch ML 2400, 3 mKit 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)

MIG-MAG accessories A 1700, A 2200 and CuSiThe 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% bybuying 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.

Electrode welding cable with electrode holder25 mm2, 4 m long, with electrodeholder and 13 mm connecting plug.Is required to weld electrodes.Order no. 551.0220.0 (PG 14)

Adaptor for basket coils K300Included in the scope of supply of theA models. Spares:Order no. 551.9020.0 (PG12)

Adaptor for small spoolsFor using plastic spools with a 200mm diameter. Spacer guarantees reliable wire feed.Order no. 620.9650.0 (PG 12)

Feed rolls A 1700 and A 2200For steel/stainless steel wires 0.6 / 0.8 mmOrder no. 620.8700.0 (PG12)

For steel/stainless steel wires 0.8 / 1.0 mmOrder no. 620.8701.0 (PG12)


For Aluminium and brazing wires 0,8/1,0 mmOrder no. 620.8701.1 (PG 12)

For aluminium wires 1.0 /1.2 mmOrder no. 620.8710.1 (PG12)

Lorch separating spray 400 mlForms a thin protective film in the gas nozzle to protect against sinteringof hot weld splashes.Order no. 551.9000.0 (PG2)

Ground cablesWith 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 250025mm2, 4m, plug 13mm, Order no.551.0120.0

Special pliers MIG-MAG4 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)

MIG-MAG protective glovesMade of high-grade, durable leather. With wear-resistant seam. What a realwelder’s glove should look like.Order no. 535.8210.0, (PG12)

40

Autoprotect X 10+11, protective level DIN 10. Converts to DIN 11. MIG-MAG/electrodeswelding. 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 5-13protective level DIN 5 to 13. Electrode/MIG-MAG/TIG. Daylight filter, sensitivityregulator. Keeps going where other helmetsgive up the ghost. Order no. 550.5313.0 (PG12)

TIG accessories A 1700, A 2200, and CuSi

Collet body for TIG torch WLV/WLT 17/26To determine the correct size, see the explanationprovided above.Size Pack Order no.


The electrode diameter, welding current and gas nozzle should be adapted to the material thickness. See the table below.

TIG torch for the A 1700Torch 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 1700Torch 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)

Ceramic gas nozzles for TIG torch WLV/WLT 17/26To determine the correct size, see the explanationprovided above.Size Pack Order no.


Collets for TIG torch WLV/WLT 17/26To determine the correct size, see the explanationprovided above.Size Pack Order no.


Tungsten electrodes, goldNew-style, lathanised, with excellent ignition properties. Longservice life. Suitable for DC and AC. Environmentallyfriendly,100 % radiation free. Length: 175 mm. For match-ing diameters, see above table.

Diameter Pack Order no.1.0 mm 10 pcs. 535.8006.1 PG21.6 mm 10 pcs. 535.8006.2 PG22.4 mm 5 pcs. 535.8006.3 PG23.2 mm 5 pcs. 535.8006.4 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 welding rods are what make the actual joint.

Stainless steel 1.4576Filler 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, 1.458350 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-alloyedsteels for operating temperatures up to appr. 300°C, coldtough 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

Material Thickn. Dia. mm Ampere Gas nozzle


3.0 1.6-2.4 90-150 64.0-6.0 2.4-3.2 140-180 7

Copper and 1.0 1.0 60-80 4copper 1.5 1.6 100-150 5alloys 3.0 2.4 150-180 6Aluminium 1.0 1.0 10-60 4

1.5 1.6 40-80 52.0 1.6 70-120 53.0 2.4 90-150 64.0 3.2 140-180 75.0 3.2 170-180 7

Right then. You have really decided to buy

yourself a welding system. Great. Question is

- which one? Sales people will promise you

the world. Rumour has it some of them have

never even held a welding torch. How can

they possibly offer you any sensible advice?

Like someone without a licence giving an

“expert” opinion about cars.

These are the types you will encounter most-

ly where everything revolves around price.

This is where you will see those tempting

offers. X Euros! and a money back guarantee

if undersold. So you buy. You take it home

and you start welding. The seam stays in one

piece, and from that day forward you firmly

believe that this is how a welding system is

simply meant to be. It stutters its way

through life. But then, you paid just 1,000

Euros. Actually you were relieved of 1,000

Euros. The follow-up costs can mount alarm-

ingly 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.

%Discount it! C

Brand quality

BBrand quality

42

Read befor

So from now on you will place your trust in

good, solid brand names. A product that has

been around a long time can’t be all bad. Or

can it? You are bound to know lousy busi-

ness people who have been around forever

against all the odds. Sometimes investors

can find themselves paying just for a label.

They pay no attention to the inner values of

their purchase. Market share, sales opportu-

nities and what not are all more important.

So as not to confuse you completely, let us

just say two sentences thing about C brand

quality: It comes from outside of Europe,

and the lion’s share of the costs you pay

goes towards sales commission and freight.

Don’t be surprised to see a white elephant

walking past your workshop.

The tendency in this category is for manufac-

turers to have nothing but the rating plate

made in Germany. Everything else comes

from all over the place. This is how B quality

brand systems are produced today. They are

300 Euros cheaper, they weld - and the hous-

ing looks highly professional. The apprentice

will just love it. But it is in the fine tuning

that everything falls apart. The specified

amperage loses all credibility after warm-up,

and certainly defies any sensible measure-

ment. Just one example: The latest B systems

come with low-cost control systems from

Chechnya. Unable to believe the price, we got

hold of one. Once we opened it up, all was

revealed. Simplistic technology. Set to age in

a few months at the outside. Sending the

wire feed off balance, causing the free burn

time of 20/100th of a sec. to shoot to 0.5

secs., meaning a continuous problem with

nozzle burnout. So you limp along for anoth-

er 2 or 3 years until one day: total failure.

Part price just 100 Euros. Telephone call 2

Euros. Outage 10 days. But then, you did pay

a whole 198 Euros less to start with. No. In

actual fact the work quality and time lost

with this stone age technology has already

cost you a lot more than you realise.

Recommendation:

As far as we are concerned, in Germany

there are three welding system producers

you can safely buy from if work quality, sat-

isfaction, 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-

ny’s foundation in 1957, development was

seen as the number one foundation stone for

the future. The photo showing strength test-

ing by standing a truck on a polyester hous-

ing, gives you some idea of how things were

done back then. Positive scepticism has been

ingrained in the Lorch gang ever since. By

far and away the first to introduce plastic

housings to the market back then. Other

manufacturers are still claiming this as

highly innovative today. But things look very

different at Lorch in the 21st century. South

German Auenwald is home to what must be

Europe’s most modern welding system facto-

ry. Logistics pure. But one thing has not

changed: Everyone is still preoccupied with

welding. And the heady enthusiasm of those

early pioneers has never left. When it comes

to developing a new welding system to ben-

efit users, our engineers and application

technology team have free rein. As much

material as they need. Time too. Which

there is plenty of in tiny Auenwald. From

the concept to the analogue and digital cir-

cuits, from the system software to that one

essential screw - everything is created

here. Because only what we build ourselves

can we be sure will work. And what we

don’t know, we fetch home to Auenwald

with the cooperation of universities and

specialist institutes. In the beginning is

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

systems end up on the scrap heap.

Sometimes even whole projects. The sys-

tems which demonstrate the greatest level

of success under development are pro-

duced and launched into the marketplace.

Where they hardly ever meet their match

among comparable products of their day.

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

quality.

The manufacture of a Lorch system is

something that just won’t be rushed. If we

used more housings made of plastic, we

could cut 21 minutes off the assembly time.

But we stick with steel and with staff who

understand about assembly precision - not

everybody does.

All dealer orders and queries are processed

online. All requests are answered. Final

inspection is fully computer automated. The

Lorch high-bay warehouse is linked to the

outside world by bar code. But when it

comes to production itself, tradition is king.

You could call it painstaking precision - and

it is precisely this that makes a Lorch sys-

tem better than anything else you can buy.

But in the final reckoning, there is one

main beneficiary in all this: You. And you

will go on reaping the benefits for years to

come. One of Lorch’s fundamental princi-

ples: In Auenwald, nobody tells lies.

43

ABrand quality

ore you buy

44

MIG-MAG

M stands for masterpiece.The 2000 series.

Still a bit hit and miss, but cheap. And with aprofessional look. Great. True, they do brakethe unit on a sloping workshop floor. Butthen there is the braked swivelcaster you see here. Youwill find it under everysingle M. Expensive, butworth it. Guaranteed tostay solid as a rock inyour trailer at the back.If you don’t want yourprecious unit to fly off youhad better tie it down.

Example 4The easiest way to fool the average craftsmanis by palming him off with a cheap controlsystem. Why? Because it costs a fraction andlooks just the same. But after just a short timethese cheap imitations will show signs of wearand tear. Your wire feed is thrown off balance,resulting in a shift in the free burning time.The result: nozzle burnout. The “best bit”: Atfirst you assume that you are at fault. Younever really realise what is going on. Evenwhen the whole control system packs upwithin four years at the outside. 80% of allsystems offered in the marketplace today fallunder this category. Every M comes with amicrocontroller. No wear. Precise, digital con-trol of every single function. Our industrialsystems all work to this high engineeringstandard. The best currently available. So yousee - there are welding systems and weldingsystems. The choice is yours.

Why is it exactly that the world and its wifewould rather be driving a Mercedes than anOpel? Looks better? More status?Is that all? Just ask a taxi driver. A cabby willmake a professional judgement based onhard business sense. After all, he drives it.Or why is it that a hammer drill will slicethrough the concrete in just 3 seconds whereothers plug away for 15 seconds to make thesame sized hole? Nobody who drills for a liv-ing would put themselves through that. It isno different if you look at our M system. Ifyou are a professional you have no choice butto opt for this degree of MIG-MAG perfection.An amateur who does the odd bit of weldingcan save a good 400 Euros by shoppingaround for some sort of welding system. Wedon’t supply this particular market and wenever will. An M from Lorch offers inner values - valueswe set out to achieve at an enormous cost interms of time and effort.

Example 190 % of all welding systems fall short of thespecified output level once they have com-pleted the warm-up phase. If the rating platesays 350 amperes, chances are that will onlyapply to a cold start. After just 5 minutes, theoutput takes a nose dive - but stealthily. Inother words while you are welding.

This type of behaviour can drive a profes-sional welder round the bend. An M will goon giving just what we promise it will afterhours. And years.

Example 2It is generally true that the sum of all detailsis what sets an object apart from the rest.Take a look at just one such detail - the knobnext to the wire insertion. This is somethingyou will be lucky to find on any other unit.But actually it is an ingenious detail. Itallows you to insert the wire without pickingup the torch. This unassuming looking knobis used to switch the wire feed then andthere. Without it, the whole process becomesan imprecise science as your eyes move back-wards and forwards between the torch switchand the wire feed roll. This knob with its sur-round costs us around 12 Euros. Others don’tbother with it, although they are perfectlyaware of its benefits. Savings like this allowthem to shave more off thepurchase price. Good forthem.

Example 3Underneath every weld-ing system are casters.Available to manufacturersin different qualities ranging in price from10 Euros for a set of four up to 98 Euros. Thequestion every producer asks is: How muchdo I invest in the bit you don’t see? Mostdecide this is a place they can afford to cutcorners. Of course they roll. But efficientbraking is quite a different matter. And theystruggle over obstacles and around corners.At Auenwald, these are the sort we mountunder our waste paper bins. We don’t see anyother valuable purpose for them. The othergroup among our competitors opt for casterswith a kick-stop brake.

45

“The 2nd M series has taken on a cult status. The MIG-MAG welding system for thin sheet and lightweight steel construction.

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 trans-

port. Special wire inlet guides made of moulded brass to ensure easier running for steel and stainless steel as well as alu-minium. Sophisticated electronics, compact central torch connection, adjustable wire roll brake, even easier operationand 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 posi-tion. 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 holderand compliance with the standards EN 60974-1 a, CE and S marks.

46

MIG-MAG

M 2040All accessories included

M 2020 All accessories included

Ideal for thin-sheet welding Ideal for thin-sheet welding Ideal for thin-sheet welding e.g. on vehicles and profile work and light steel work

Method MIG-MAG welding MIG-MAG welding MIG-MAG welding

Welding range 30-140 A 25 -170 A 25 - 210 A

Settings 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

Weldable wires, aluminium 1.0 mm 1.0 mm 1.0-1.2 mm

Mains voltage 230 V 230/400 V 230/ 400 V

Material Steel/stainless steel/aluminium Steel/stainless steel/aluminium Steel/stainless steel/aluminium

Material thickness, steel 0.8-3 mm 0.8-5 mm 0.8-8 mm

Material thickness, aluminium 2 mm 2-3 mm 2-5 mm

Set wire diameter 0.6 mm/0.8 mm 0.6 mm /0.8 mm 0.6 mm/0.8 mm

Order number (PG12) 202.2020.1 202.2040.1 202.2060.1

Scope of delivery: System complete with torch System complete with torch ML 1500, System complete with torch ML 1500,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), groundvolume and content manometer, content manometer, mains cable 4 m with cable 25mm2, 4m, pressure reducer with

mains cable 4 m with schock-proof plug, CEE16-plug, mains adaptor 230V/400V volume and content manometer, mains cablefitted 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, fittedNew: with basket coil adaptor New: with basket coil adaptor gas hose, operating manual.

as standard. as standard. New: with basket coil adaptoras standard.


47

All-round system for sheet and light All-round system for sheet All-round system for sheetto medium steel work and medium steel work 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 System complete with torch System complete with torchML 2500, 3 m; ground cable ML 2500, 3 m, ground cable ML 3600, 3 m; ground cable

25 mm2, 4 m, pressure reducer with 25 mm2, 4 m, pressure reducer with 35 mm2, 4 m, pressure reducer withvolume and content manometer, volume and content manometer, volume and content manometer,

mains cable 4 m with CEE 16-plug, mains cable 4 m with CEE 16-plug, mains cable 4 m with CEE 32-plug, fitted gas hose, fitted gas hose, fitted gas hose,

operating manual. operating manual. operating manual.New: with basket coil adaptor New: with basket coil adaptor New: with basket coil adaptor

as standard. as standard. as standard.

M 2090, with 4-roll feedAll accessories included

M 2095, with 4-roll feedAll accessories included


More accessories on page 50

48

MIG-MAG

When you buy a Lorch system

we will provide all the knowledge you need.

Page 79.

M 3000.Middle and heavy weight champion.

Ideal with automatic adjustment.

M 3050With or without wire feeder

M 3070With or without wire feeder

49

M 3050 M 3070

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 separatewire 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 onlyway to guarantee trouble-free welding of all types of wire. The housing is just as stable as the gas cylinder holder. The trans-

former-inductor power unit features such a finely tuned 24-step power characteristic that the ideal arc is achieved for every con-ceivable 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 auto-matic 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-endtechnology 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. Andthe 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 regu-late the wire speed and wire feed on the spot. Which allows you to concentrate on what you are doing instead of walking back-

wards and forwards to the unit.

In water-cooled systems, an exemplary centrifugal pump operates on demand and keeps noise to a minimum. Caution: In mostcases, 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 25-350A/2x12 settings 30-400A/2x 12 settingsDC at max. current (25/40°) 45%/30%/350 A 45%/30%/400ACurrent at 100 % DC (40 °) 210 A 240 AMains voltage 3x400 V 3x400 VWeldable wires steel / alum 0.6-1.6 mm / 1.0-1.6 mm 0.6-1.6 mm / 1.0-1.6 mmMaterial MIG-MAG Steel / stainless steel / aluminium Steel / stainless steel / aluminiumRecommended material thickness steel / alum. from 0.8 / from 2 mm from 0.8 / from 2 mmSet wire 1.0 / 1.2 mm 1.0 / 1.2 mm Torch type (gas/water) ML 3600 / MW 5500 - / MW 5500Compact system, gas 203.3500.0, PG 12Compact system, water 203.3510.0, PG 12 203.3710.0, PG 12Feeder system, gas, 1m interm. hose set 203.3500.1, PG 12Feeder system, gas, 5m interm. hose set 203.3500.5, PG 12Feeder system, gas, 10m interm. hose set 203.3501.0, PG 12Feeder system, water, 1m interm. hose set 203.3510.1, PG 12 203.3710.1, PG 12Feeder system, water, 5m interm. hose set 203.3510.5, PG 12, 203.3710.5, PG 12Feeder system, water, 10m interm. hose set 203.3511.0, PG 12 203.3711.0, PG 12Other lengths on request.

Scope of delivery: System, torch with 4 m hose set, ground cable 50 mm2, 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.

Lorch separating spray 400 mlForms a thin protective film in the gas nozzle to protect against sinteringof hot weld splashes. Only ever sprayinto the nozzle from the side, neverfrom the front, as this can clog upthe gas outlet apertures on theneck of the torch.Order no. 551.9000.0 (PG2)

Special pliers MIG-MAG4 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 glovesManufactured to the specificationsof the Lorch specialists. Made ofhigh-grade, durable leather. Withwear-resistant seam. This is whata 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 qualitycounts. Steady, reliable currenttransmission is imperative toa neat, tidy job. Defective orworn ground cables really dohave to be replaced.

M 2020 to M 209025mm2, 4m, plug 13mm, order no.551.0120.0M 209535mm2, 4m, plug 13mm, order no.551.0130.0M 3050 and 307050mm2, 4m, plug 13mm, order no.551.0140.0all (PG14)

Autoprotect X 10+11Fixed protective level DIN 10. Can be converted forfixed protective level DIN 11 using the supplied spare glass. Reasonably priced, tough autoprotecthelmet for MIG-MAG and electrode welding. Not suitable for TIG welding. Solar cells mean thehelmet is always ready for service without theneed for a battery change.Order no. 550.5311.0, (PG12)

Autoprotect Flex 9-13With adjustable protective level from DIN 9 to 13,providing reliable protection and an optimum viewfor electrode, MIG-MAG and TIG welding. Conven-ient adjustment from outside. The light-darkswitching time can be set as required, e.g. toprotect eyes against weld afterglow. The detachablesensor bar allows you to eliminate the influenceof the ambient light and also ensure reliabledarkening in all welding positions. Solar cells, without battery.Order no. 550.5312.0, (PG12)

Autoprotect Multiflex 5-13Highlight. 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 toprevent dazzle by weld glow. Grinding mode –clear vision for grinding. Solar cells, without battery.Order no. 550.5313.0, (PG12)

Lorch coolant LCL 20For 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

Accessories for the M 2000 and M 3000 series.

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)





1.4316, 0.8 mm for welding stainless steel (V2A). Small spool D200, 5.0 kg,Order no. 590.0208.1 (PG12)

Adaptor for small spoolsThis adaptor is required when workingwith plastic spools with a 200 mm dia. It is used as a spacer and guaranteesreliable wire feed.Order no. 620.9650.0 (PG 12)

Adaptor for basket coils K300basket coil adaptor K300 is requiredfor placing basket coils into thewire roll fixture. This is includedin the scope of delivery of the M series.To order spares:Order no. 551.9020.0 (PG12)

51

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 recommendthis way of easing the workload - by letting the wheelstake 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 adaptedin line with the welded wire. The necessary equipmentis listed in the technical data.

Feed rolls M 2020 to M 2080





Feed rolls for M 2090, M 2095, M 3050, M 3070Where 4-roll drive is used for theseunits, 2 feed rolls are always required.Please remember when ordering.







Accessories for the M 2000 and M 3000 series.

Original equipment kit for torch ML 1500, 3 m

Kit including the most important torch wearing parts at anaffordable 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)


Kit including the most important torch wearing parts at anaffordable 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,3 retaining springs,1 contact tip holder, 1 Lorch separating spray 400 ml.

Order no. 551.1023.0 (PG2)


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. 551.1036.0 (PG2)

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. 551.1055.0 (PG02)

52

Torch original equipment kit in a case Each case containing thedifferent accessory kits shownon the left - but packaged safelyand neatly in a sturdy plasticcase with handy compartments.

Order no. 551.0490.1 (PG12), for ML 1500Order no. 551.0490.2 (PG12), for ML 2500Order no. 551.0490.4 (PG12), for ML 3600Order no. 551.0491.0 (PG12), for MW5500

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 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)

Set of torch wearing parts for MW 5500 Case containing the following main wearing parts 3 tapered gas nozzles10 contact tips 1.0 mm10 contact tips 1.2 mm1 contact tip holder1 gas diffuser.Order no. 551.2155.0 (PG12)

Only original complete burners from Lorch

Ergonomics, a highly flexible hose set, wear-proof torch neckand optimum current transmission all interact in thesetorches to ensure optimum welding characteristics and aservice life that pays dividends.

Torch ML 1500 for the M 2020, M 2040, M 2060ML 1500, 3 m long, order no. 503.1500.3 (PG2)ML 1500, 4 m long, order no. 503.1500.4 (PG2)

Torch ML 2500 for the M 2080, M 2090ML 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)

Torch ML 3600 for the M 2095, M 3050, gas-cooledML 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-cooledMW 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 aluminiumHow to convert your torch for welding aluminium wire 1.0 / 1.2 mm. Kit contains: Special combination teflon liner with flange-mountedbrass spiral to extend the current transition zone inthe torch neck, O-ring, collet and brass support pipe. Theset can be used for torches up to 4 m in length. To preventwire damage, we recommend using 1.2 mm wire with a 3m torch. Please order the matching contact tips and alu-minium feed rolls separately.Order no. 551.2014.0 (PG2)

Conversion kit stainless steel, 0.6/0.9 mmHow to convert your torch for welding stainless steel wire.Kit contains: Special combination carbon-teflon liner with flange-mounted brass spiral to extend the current transition zonein the torch neck, O-ring, collet and brass support pipe.The set can be used for torches up to 5 m in length. Pleaseorder the matching contact tips and aluminium feed rollsseparately. Order no. 551.2015.0 (PG2)

Conversion kit stainless steel, 1.0/1.2 mmHow to convert your torch for welding stainless steel wire1.0 / 1.2 mmKit contains: Special combination PA liner with flange-mounted brassspiral to extend the current transition zone inthe torch neck, O-ring, collet and brass support pipe. Theset can be used for torches up to 5 m in length. Pleaseorder the matching contact tips and aluminium feed rollsseparately. Order no. 551.2015.2 (PG2)

53

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)MW5500 order no.535.8400.5 (PG02)

Liners for ML 1500, ML 2500, ML 3600Also to fit MS 15, MS 25, ML 36

Liner for wire 0.6 - 0.9 mm, colour code blueFor 3 m torch, (PG02), order no. 535.8300.1For 4 m torch, (PG02), order no. 535.8300.2

Liner for wire 1.0 - 1.2 mm, colour code redFor 3 m torch, (PG02), order no. 535.8300.3For 4 m torch, (PG02), order no. 535.8300.4For 5 m torch, (PG02), order no. 535.8300.5

Liners for MW 5500, Wire 1.0 - 1.2 mmFor 3 m torch, (PG02), order no. 535.8301.0For 4 m torch, (PG02), order no. 535.8302.0For 5 m torch, (PG02), order no. 535.8303.0

AccessoriesM 2000M 3000

54

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

For aluminium wire

1.0 mm M6 5 535.8101.5

1.2 mm M6 5 535.8101.6

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

For aluminium wire

1.0 mm M6 5 535.8106.5

1.2 mm M6 5 535.8106.6

Contact tips 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

For aluminium wire

1.0 mm M8 10 535.8108.5

1.2 mm M8 10 535.8108.6

For gas nozzles, (PG02)

For ML 1500 10 535.8100.9

For ML 2500 10 535.8105.9

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

Gas diffuser, (PG02)

For ML 3600 2 535.8107.3

For MW 5500 2 535.8108.8

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 MW 5500, (PG02)



55

MIG-MAG

To date it all revolved around MIG-MAG.Corrosion protection and higher-strength

steel sheet are ringing the changes.What next?

MIG-brazing

Whoever processes high quality steel today buysthe M 3030 automotive. The future demands it. Acombined MIG brazing and MIG-MAG welding unitis the logical solution. Up until now it was all sim-ple sheet. Little thought was given to the quality ofproperties required from high quality thin sheetwelding 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 delayedactivation of the airbag, sheet structure or corrosion resistance may be destroyed.Already today, MSG brazing is mandatory in every Opel workshop. Tailoredblanks, modern high strength steels and the benefits of MIG brazing are makingyour welding machine obsolete. High strength steels are all set to take over in thefuture. Times have changed. MIG brazing units are already an established featurein wide-ranging fields such as the automotive industry, steel furniture manufac-ture, container construction and many more.

MIG brazing is a hard soldering technique in which the required process energyis generated by an electrical arc. A MIG-MAG welder will easily get to grips withit. Instead of steel wire, the arc melts a solder wire. The process temperature iswell below that needed for MIG-MAG. Sheet is not melted, the solder creates afirm joint that is gentle on the material. The benefits of MIG brazing include min-imal material distortion and low heat generation. Ideal for thin sheet. No changeoccurs in the base material. Strength is uncompromised. Welding state-of-the-artmaterials. No corrosion of the brazing seam. In coated sheet, the zinc coatingremains undamaged even in the brazing seam zone. Corrosion resistance is guar-anteed without the need for any subsequent treatment. Optimum gap bridgability. Minimal spatter and a soft brazing seam reduce theneed for reworking. So if thin sheet is an issue for you, the M 3030 automotiveawaits. As far as we are concerned, its cost-to-performance ratio among avail-able systems is second to none.

The Lorch M 3030 automotive.MIG brazing and MIG-MAG in one.The answer to the stream of new

materials and regulations.

56

Method MIG brazing/MIG-MAG welding

Brazing-/ Welding range 30 – 260 A / 11.4 – 27 VSettings 41 Digastep performance stepsDuty cycle at max. current (40°) 35 % at 260 AWelding current at 60 % DC (40°) 200 AWelding current at 100 % DC (40°) 160 AWeldable wires steel 0.6 - 1.2 mmWeldable wires aluminium 1.0 - 1.2 mmBrazable wires 0.8 – 1.0 mmMains voltage 3 x 400 VMaterial Steel/stainless steel/aluminiumMaterial thickness steel 0.8 – 10 mmMaterial thickn. alum. (welding only) 2 - 6 mmSet wire diameter 0.8 mm / 1.0 mm brazing wireOrder number (PG12) 203.3300.0 Scope of delivery: Unit with remote-control torch ML 2400 PowerMaster, 3 m; MIGbrazing torch set with combination carbon-teflon liner; ground cable 35 mm≈ long;pressure reducer with volume and contents manometer, adaptor for basket coilsK300; mains cable 4 m with CEE 16-plug, fitted gas hose, operating manual.

Active Induction System (AIS). Ignition without spatter, braz-ing and welding with a constant arc even in the lower powerrange. No arc breaks or spatter. AIS automatically controlsthe induction coil under all conditions. This is our secret. Ifcompared to a car, it would be the perfect adjustment of thesuspension in a fraction of a second.

Totally digital – the whole process.Arc control, ignition control, gas man-agement system, wire burn-back withoutelectrode sticking, wire speed control.Built-in diagnostics. Tacking, continuous,spot or interval.

Job memory. The Tiptronic.100 work values can be saved and activated with a switchat the torch. Complete sets of procedures. Manufacturer’sguidelines. All stored – time-saving.

Undisturbed wire feed due to precise 4-roll drive system.

Digital display for voltage and current.Voltage and current values will be prescribed by futurerepair guidelines. All integrated ready for action.

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 bestparameters are applied. Stored in a data base – with the knowl-edge of the best welders. By setting to the expert mode, special-ists can always intervene in the system. But actually there is noreason why they should.

No more experimenting with step switch-es. 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 theGerman Federal Ministry of Research and Development.

57

The new Power-Master-Torch. Integrated remote control anddisplay, wire speed control, power and tiptronic can all be con-trolled at the torch. This would normally be an expensive extrafeature.

So inexpensive. How is that possible? Just € 2,930.-We don’t believe that your job is to build a steel bridge acrossthe River Nile, so the M 3030 is not equipped to perform sucha task. Neither do we believe that you require a new pulse-arcunit for your new tasks. In our opinion, and from our experi-ence, you need the M 3030 Automotive. It would be easy torecommend 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, pressurereducer, ground cable.

Accessories M 3030 automotive

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)

58

Ground cables with ground clamp and plug Steady, reliable current trans-mission is imperative to a neattidy job. Defective or wornground cables really dohave to be replaced.35mm2, 4m, plug 13mm, Order no. 551.0130.0

Adaptor for basket coils K 300The basket coil adaptor K 300 is required when using basket coils in the wire roll holderOrder no. 551.9020.0 (PG12)

Adaptor for small spoolsThis adaptor is required when 200 mmdiameter spools are used. It serves as a spacer and guarantees reliable wireinsertion.Order no. 620.9650.0 (PG 12)

MIG-MAG protective glovesMade of high-grade, durable leather. Withwear-resistant seam. What a realwelder’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)

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 rollssupplied for the M 3030 allow two different diameters to beprocessed. Fitted as standard with 0.8/1.0 mm aluminium feedrolls for processing brazing wires. The dual drive system alwaysrequires 2 feed rolls.

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)

Autoprotect X 10+11, protection level DIN 10. Converts to DIN 11. MIG-MAG /Electrode welding. Order no. 550.5311.0 (PG12)

Autoprotect Flex 9-13Protection level DIN 9 up to 13. Electrode/MIG-MAG/TIG. Dark/light switching. Sen-sor web. Order no. 550.5312.0 (PG12)

Autoprotect Multiflex 5-13 Protection level DIN 5 up to 13. Electrode/MIG-MAG/TIG. Daylight filter, sensitivityregulator. Goes on where normal helmetsgive up the ghost. Order no. 550.5313.0 (PG12)

Lorch separating spray 400 mlForms a thin protective film in the gas nozzle to protect against sinteringof hot weld splashes. Order no. 551.9000.0 (PG2)

Special pliers MIG-MAG4 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)

Torch ML 1500 PowerMaster for M 3030 automotiveSpecifically for car body work. Compact, handy design. Max.current load 200 A. When used for MIG brazing, brazingtorch set order no. 551.2015.0 is additionally required. Forhigher outputs, use torch ML 2400 PM.ML 1500 PM, 3 m, order no. 503.1501.3 (PG02)

Torch ML 2400 PowerMaster for M 3030 automotiveUniversal 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)

Spare torch necks to fit:ML 1500 PowerMaster, order no.535.8400.1 (PG02)ML 2400 PowerMaster, order no.535.8400.3 (PG02)

Liners for ML 1500 PM, ML 2400 PMLiner for steel wire 0.6 - 0.9 mm, colour code blueFor 3 m torch, (PG02), order no. 535.8300.1For 4 m torch, (PG02), order no. 535.8300.2Liner for steel wire 1.0 - 1.2 mm, colour code redFor 3 m torch, (PG02), order no. 535.8300.3For 4 m torch, (PG02), order no. 535.8300.4For 5 m torch, (PG02), order no. 535.8300.5

59

PowerMaster torch. Regulate power and speed byremote control in the torch itself.

Conversion kit aluminium 1.0 - 1.2 mmContents: Special combination teflon liner with flange-mounted brass spiral to extend the current transition zonein 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 witha 3 m torch. Please order the matching contact tips andaluminium feed rolls separately.Order no. 551.2014.0 (PG2)

MIG brazing torch set, 0.6-1.0 mm, also for stainless steel. Contents: Special combinationcarbon-teflon liner with flange-mounted brass spiral toextend 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)

Contact tips for torch, 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 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

For aluminium wire

1.0 mm M6 5 535.8106.5

1.2 mm M6 5 535.8106.6

Holding 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

Gas nozzles, plug-in, for torch ML 1500 PM, PG2




Gas nozzles, plug-in, for torch ML 2400 PM, PG2



60

The rating plate. The bearer of truth.Or the last chance tobend the truth a little ??You would imagine that this type of rating plate has to presentthe bare facts. The truth. We believe that the truth is what youget from Auenwald. Because we pledge and guarantee not todeceive anyone. We know manufacturers who do. Even on therating plate. So we send our development engineers for 34days a year to sit on committees and advisory panels at lead-ing electrical engineering industry associations such as theDKE and the ZVEI, as well as the DIN standardisation agency,to help safeguard your interests.

The protection class IPProtection classes according to type of housing (IP Code) areregulated by European standard EN 60529. Welding currentsources must comply with protection class IP 21S as a mini-mum requirement. Always remember: Welding currentsources which have to be used outdoors must comply with atleast protection class IP 23. Anyone offering assembly unitsprotected to IP 21 should be treated with suspicion.

The S markOnly units complying with regulations for welding in environ-ments subject to high levels of electrical risk may bear thismark. High levels of electrical risk occur, for instance, whenthe welder is forced to make contact with electrically liveparts. Workplaces in which the clearance from surroundingelectrically conductive parts is less than two metres also quali-fy as at high electrical risk. The same applies to wet or dampworkplaces in which the electrical resistance of work clothingor human skin can be reduced.

Watch out!A high current rating is good. But is the relevant standardisedworking voltage right? It is only the current and voltagetogether which determine the necessary melting rate.Don’t be fooled by illusory current values.

A promisis a prom

61

The duty cycleThis is real test of honesty. In a MIG-MAG welding unit with a60% duty cycle at 220 A this means: Welding current 220 A.The standardised welding voltage is 25V. The ambient temper-ature is set at 400C.The measurement period is always 10 minutes. 60% means 6minutes of welding, 4 minutes break. Hours, days, weeks.So be wary of statements like ...200 A at 250C ambient temper-ature or ...60% duty cycle at intervals of 5 minutes, which areclearly in contravention of the standard.

The standardsEN 60974-1 for Europe, VDE 0544 Part 1 for Germany. Theycontain the same thing, and are applicable for all weldingcurrent sources used for arc welding. Duty cycle, mechanicaland electrical safety, type and piece testing etc. are all laiddown in these standards. Why doesn’t everyone stick tothem?

se mademise kept

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

Technically speaking, inverter units do not

have a lot in common with welding transform-

ers. They are complicated devices with a low

weight and compact design, but with excellent

welding properties. This technology is very

expensive and entails a great deal of develop-

ment work. Something that many manufactur-

ers dread and therefore buy in from "else-

where" abroad. After assembly they stick their

own trademark, and in some cases "Made in

Germany", on the device and Bob's your

uncle. Good ? Without their own experience,

at the mercy of quality and know-how from

"elsewhere". Let's assume you need a spare

part after a few years. Just remember, we

build our own inverters and know why.

A question of trust.

The duty cycle (DC).

No unnecessary compulsory breaks please.

Mains voltage cannot be converted into weld-

ing 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

for cost reasons. The consequence is that the

unit heats up faster. And what happens? Your

machine has to cool down and switches itself

off. The more often this happens, the worse it

is for the service life of the machine.

The relationship between the welding time

and cooling phase is called the duty cycle.

The standard EN 60974-1 is applicable when it

comes to determining the duty cycle of profes-

sional units. (The standard EN 50060 applies

for devices for limited use and hobby purpos-

es.) The duty cycle is determined within a

cycle period of 10 minutes (100%) A duty cycle

of 60% thus means that the welding time is 6

minutes (60%) and the cooling time 4 minutes

(40%).

62

The inverter. Where honesty is the best policy.

A new type of welder the inverter has arisen

from of the development of power electronics.

The mains current is firstly converted into a

direct current by diodes and then electronical-

ly "chopped" before being "smoothed". This is

the only way to achieve a high transmission

frequency. The consequence: a smaller and

lighter transformer. Sounds simple, but it

involves very complicated electronics.

There are nothat give “mor

they

63

Amperes! Doesn’t mean a lot on its own.

The engine of a VW Golf can be rebored so

that it shoots along at 250 kp/h. The ques-

tion is, how would it handle? Hopefully it

would still run straight ahead. A similar situ-

ation applies for welding devices when it

comes to amperes (horse power). These tell

you how much current is flowing in the arc.

That's all. But welding, properties, ignition,

inductor combination, no-load voltage, work-

ing voltage, optimum penetration and much

more also have to be taken into account.

Only when all these aspects are optimised do

you end up with a useful unit. This is

expressed in what are commonly called weld-

ing 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 perfor-

mance has its price – though with us this

does not have to be unnecessarily high.

Mains fuses.

Some have their limitations.

Let's assume you want to weld, working with

a 230 V (lighting) power supply. But the

mains fuse keeps blowing. Tiresome. Or you

are working with a long extension lead and

you simply don't have enough power for

welding! We would like to explain briefly

what exactly happens here. The energy need-

ed in the arc or melt has to come directly

from the mains supply. We have developed

SPM (SinePowerManagement) specially for

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.

not many thingsore” back than

receive.Standard data can be used to compare vari-

ous welding accessories. The duty cycle is

determined at a certain ambient temperature.

Until recently this was 25°C, i.e. a tempera-

ture corresponding to average use in central

Europe. This has now been raised to 40°C. In

some cases, during the transitional phase, this

led to inaccurate comparisons. Which is why

we specify values at both 25°C and 40°C for

most of our welding accessories. You have the

right information, and can compare for your-

self. In principle, the higher the duty cycle,

the fewer the unavoidable breaks.

50

Fact is: Units in this power class usually weigh around 100kg. These get either weight lifted in theworkshop like stone age monoliths or transported on site with a crane, if there happens to be one. Thisis history. Two newly developed plasma-cutting-inverter are playing this easy (to-carry) part in the mar-ket now. They cut bolt upright, circular, around angles, forward, to the left and to the right, all electricalconductive 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 andconstruction work, air condition technology, on site.

For cutting, preparation of welding seams, joint planing, hole pricking. And should you ever forget thecombination 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 materialscan be accomplished with a neat cutting edge. Microprocessor controlled plasma logic enables the cut-

ting of hole sheets and grates without interruption.

Plasma-cutting is quite simple: you need the plasma cutting unit and compressed air. The producedplasma 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 cut-ting 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 unitequipped with a conventional transformer. Substantially lower energy consumption for one. And we allknow the cost of electricity. Soft-start ignition also places minimum stress on the cutting electrodes. Afar longer service life and clearly improved cutting quality. Benefits you can start enjoying as soon as

you like.

64

The Lorch inverter plasma cutting units.

Z 70 and Z 110.4 times hotter than the sun itself.

Incredible speed, durability, mobility.

Plasmacutting

66

Scope of delivery: Unit complete with 6m torch type LCT 80 for model Z 70 or type LCT 150 for model Z 110. Ground cable25mm≈; air pressure nozzle fitting, pressure reducer with filter for compressed air, mains cable 4 m with CEE 16 plug at modelZ 70 or CEE 32 plug at model Z 110. Operating manual. Incl. wearing part set for the cutting torch.

Inverter plasma cutting unit Z 70, including torch

30 kg high-end durable technology, 70 Ampere

The technology: Primary Inverter-Powerpack. Minimal energy consumption. Controlled pilot arc for reliable ignition. Infinitelyvariable adjustment offers a cutting result ideally adapted to the material thickness, resulting in neat, precise cutting edges andoptimised work speeds. Microprocessor controlled logic: high-frequency ignition and pilot arc for no-contact ignition. Soft switch-

ing for minimum strain on nozzles, digital display of cutting current and compressed air. Air flow control, air test function forconvenient pressure adjustment. Automatic cool air post-flow noticeably increases the durability of the wearing parts. Digitalsecurity 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 tothe central mounting system. Interface for automatic solutions

Workshop trolleyStraighten up out of that crouchposition. This is the ergonom-ically optimum position for theequipment. For fast, pleasantworking. The base makesa perfect resting surface.Order no. 570.3001.0 (PG 12)

Inverter plasma cutting unit Z 110, including torch

31 kg go down to 42 mm depth, 110 Ampere

Z 70 Z 110Method Plasma cutting Plasma cuttingSetting range cutting current inf. variable 22-70 A 25-110 ACutting current at 100% DC (40°C) 50 A 60 ADuty cycle at max. current (40°C) 60 % (70 A) 35 % (110 A)Mains voltage 400 V 400 VMains fusing 16 A tr. 32 A tr.Measurements appr. (LxWxH) 650x260x470 mm 650x260x470 mmWeight 30 kg 31.5 kgAir consumption 170 l/min 200 l/minAir pressure 5.5-7 bar 5.5-7 barMax. separating/quality cut with steel 22 / 17 mm 37 / 32 mmMax. separating/quality cut with aluminium 17 / 12 mm 27 / 22 mmMax. separating/quality cut with stainless steel 18 / 14 mm 30 / 24 mm

Order no. 321.0007.0 (PG 12) Order no. 321.0011.0 (PG 12)

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)

67

Complete torch LCT 150Plasma cutting torch with central connection and 6 m long hose set. With original equipment set: 1 cutting elec-trode, 2 cutting nozzles, 5 spacer springs, 1 flowmeter.Order no. 511.9515.0, PG 2

Torches and wearing parts for the Z.

Complete torch LCT 80Plasma cutting torch with central connection and 6 m long hose set. With original equipment set: 1 cutting elec-trode, 2 cutting nozzles, 5 spacer springs, 1 flowmeter.Order no. 511.9507.0, PG 2

Plasma cutting torch LCT 80, PG 2Pos. Order no. Pack Name10* 535.8503.0 2 Diffusor20* 535.8503.1 5 Cutting electrode, short30* 535.8503.2 2 Gas diffuser40 535.8503.3 5 Cutting nozzle 1.0 < 50A40 535.8503.4 5 Cutting nozzle 1.1 40-60A40* 535.8503.5 5 Cutting nozzle 1.2 50-80A50* 535.8503.6 1 Protective cap18.7060* 535.8503.7 10 Spacer spring standard cut70 535.8503.8 1 Spacer nozzle 80 535.8503.9 1 Spacer nozzle90 535.8504.0 1 Torch trolley (PG14)Long design and for contact cutting15 535.8504.2 2 Diffusor, long25 535.8504.3 5 Cutting electrode, long45 535.8504.4 5 Cutting nozzle, long 1.2130 535.8504.5 2 Contact nozzle, long

4-point seating, vertical cut/template2-point seating, oblique cut/mitre

Plasma cutting torch LCT 150, PG 2Pos. Order no. Pack Name10* 535.8500.0 2 Diffusor20* 535.8500.1 5 Cutting electrode short30* 535.8500.2 2 Gas diffuser 40 535.8500.3 5 Cutting nozzle 1.4 50-80A40* 535.8500.4 5 Cutting nozzle 1.6, 70-120A40 535.8500.5 5 Cutting nozzle 1.8, 100-150A40 535.8500.6 5 Cutting nozzle 3.0 gouging50* 535.8500.7 1 Protective cap cylindrical60* 535.8500.8 10 Spacer spring standard cut70 535.8500.9 1 Spacer nozzle 80 535.8501.0 1 Spacer nozzle 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 ring110 535.8501.4 5 Cylindrical nozzle guard ring 120 535.8501.5 5 Tapered nozzle guard ring 140 535.8501.6 1 Spacer nozzle 150 535.8501.7 1 Spacer nozzle Long design and for contact cutting25 535.8502.0 5 Cutting electrode, long45 535.8502.1 5 Cutting nozzle, long 1.4 50-80A45 535.8502.2 5 Cutting nozzle, long 1.7 70-120A45 535.8502.3 5 Cutting nozzle, long 1.9 100-150A55 535.8502.4 1 Protective cap130 535.8502.5 2 Contact nozzle, long

4-point seating, verticalcut/template2-point seating,oblique/mitred cut

Contact cut, cylindrical, vertical and mitre

Contact cut round,vertical and mitre

130 60 70 80 90 130 60 70 80 90 140 150

10

20

40

50

10

20

30

40

50

15

25

30

45

50

25

45

55

3030

100

58

110 120

* = Original equipment

Cutting quality and safety during cutting depend on the qualityof the torch. Experimentation is not an option here.

68

LorchAUTOprotects

What the eye doesn’t see, the hand cannot reach.

We don’t manufacture this helmet ourselves and it was not born in Auenwald. It doesn’t even come from Germany, because wecould 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 onignition means an almost linear conversion at the speed of light. This automatic protection against temporary blinding is also aperfect, 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 nothing to compromise optimum ear protection against UV radia-

tion. A headband design with facility for a wide range of different adjustments helps optimise wearing comfort .

Order no. Name (helmets and parts PG 12)550.5320.0 Helmet shell cmpl. with headband X10+11550.5320.2 Helmet shell cmpl. with headband Flex 9-13550.5320.4 Helmet shell cmpl. with headband Multiflex 5-13535.8700.0 Spare lenses, scratchproof X10+11 / pack of 10535.8700.2 Spare lenses, scratchproof Flex 9-13 / pack of 5535.8700.4 Spare lenses, scratchproof Multiflex / pack of 5535.8700.6 Spare lenses, internal / pack of 5 (all types)535.8700.8 Headband cmpl. including sweatband535.8701.0 Spare cartridge for X 10+11535.8701.2 Spare cartridge for Flex 9-13535.8701.4 Spare cartridge for Multiflex 5-13535.8701.6 Leather head and neck protector (all types)535.8701.7 Leather chest protector (all types)535.8701.8 Sweat band cotton / pack of 2535.8701.9 Helmet adaptor for work safety helmets (all types)

Autoprotect Multiflex 5-13Highlight with adjustable protectivelevel DIN 5 to 13. Electrode, MIG-MAGand TIG. Sensors and daylight filtersdetect the arc, and the sensitivity regula-tor controls response in every welding sit-uation. Wherever “normal” helmets giveup the ghost - low welding current, fastarc changes, welding around corners withconcealed arc, reflective surfaces - youcan rely on the Autoprotect Multiflex tostay safely darkened.Adjustable delay time opening to preventdazzle by weld glow. Grinding mode –clear vision for grinding. Solar cells, with-out battery.Order no. 550.5313.0 (PG12)

Autoprotect Flex 9-13With adjustable protective level fromDIN 9 to 13, providing reliable protec-tion and an optimum view for electrode,MIG-MAG and TIG welding. Convenientadjustment from outside. The light-darkswitching time can be set as required,e.g. to protect eyes against weld after-glow. The detachablesensor bar allows you to eliminate theinfluence of the ambient light and alsoensure reliable darkening in all weldingpositions. Solar cells, without battery.Order no. 550.5312.0 (PG12)

Autoprotect X 10+11Fixed protective level DIN 10. Can be con-verted for fixed protective level DIN 11using the supplied spare lens. Reasonablypriced, tough autoprotect helmet for MIG-MAG and electrode welding. Not suitablefor TIG welding. Solar cells mean the hel-met is always ready for service withoutthe need for a battery change.Order no. 550.5311.0 (PG12)

Ignition: Instantaeneous darkening,light/dark switching time

0.001 of a second.

Torch and welding rod, ideally positioned.

69

70

Welder’s acWelding accessoriesProfessional welding equipment with highly flexible welding cable, electrode holder and ground clamp Protective shield EN 166 Welding glasses DIN 4646/4647Wire brush and slag hammer

25 mm2, , cable: 4 m electrode,3 m ground, plug 9Order no. 550.5506.0 (PG14)

25 mm2, , cable: 4 m electrode,3 m ground, plug 13Order no. 550.5503.0 (PG14)

35 mm2, , 2 x 4 m, plug 13

Order no. 550.5504.0 (PG14)

50 mm2, , 2 x 4 m, plug 13Order no. 550.5505.0 (PG14)

Electrode welding cable with electrode holder and plug

Design Order no. (PG14)

25 mm2,4 m long,plug 9mm 551.0210.0

25 mm2,4 m long,plug13mm 551.0220.0

35mm2,4m long,plug13mm 551.0230.0

50 mm2,4m long,plug13mm 551.0240.0

70 mm2,4m long,plug13mm 551.0250.0

Ground cables with ground clamp and plug

Design Order no.(PG14)

25mm2, 4m long, plug 9mm 551.0110.0

25mm2, 4m long, plug 13mm 551.0120.0

35mm2, 4m long, plug 13mm 551.0130.0

50mm2, 4m long, plug 13mm 551.0140.0

70mm2, 4 m long, plug13mm 551.0150.0

Welding cable extensions with cable coupler and cable plug


25 mm2,3m long, plug 9 mm 551.0016.3

25 mm2,3m long, plug 13mm 551.0025.3

35 mm2,5m long, plug 13mm 551.0035.5

50 mm2,5m long, plug 13mm 551.0050.5

95 mm2,5m long, plug 13mm 551.0095.5

Electrode holder


Electrode holder 200 A 550.0050.0



ground clamp

Design Order no.(PG12)Quick earth plug 200 A, M 6 550.0102.0 Quick earth plug 400 A,M10 550.0103.0 Quick earth plug 600 A,M10 550.0104.0

Welding cable plug Design Order no.(PG12

Cable plug 10-25 mm2, plug 9 665.7310.0




Welding cable couplers Cable coupler 10-25 mm2, for plug 9 mm 665.7210.0Cable coupler 35-50 mm2, for plug 13 mm 665.7220.0Cable coupler 50-70 mm2, for plug 13 mm 665.7230.0

Cable coupler 70-95 mm2, for plug 13 mm 665.7240.0

71

ccessoriesSpecial pliers MIG-MAG4 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 glovesMade of high-grade, durable leather. With wear-resistant seam. What a realwelder’s glove should look like.

Order no. 535.8210.0 (PG12)

High-grade TIG glovesSupple 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 reducerArgon/mixed gas CO2

Order no. 570.9203.0 (PG14)

Slag hammerAll 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)

Protective shield

Manual mask EN 166, PE blackOrder no. 550.5120.0 (PG12)

Welding glasses10 spare glasses, 90 x110 mm, clear Order no. 535.8200.1(PG12)5 welder’s protective glasses DIN EN 166/169, 90 x110 mm, protective level 9Order no. 535.8200.2 (PG12)5 welder’s protective glassesDIN EN 166/169, 90 x110 mm, protective level 10Order no. 535.8200.3 (PG12)5 welder’s protective glassesDIN EN 166/169, 90 x110 mm, protective level 11Order no. 535.8200.4 (PG12)

72

Model H140 H150 H180c H180tWeldingSetting range electrode 230 V A / V 5-140A / 20.2-25.6V 5-150A / 20.2-26.0V 5-150A / 20.2-26.0V 5-150A / 20.2-26.0VSetting range electrode 400 V A / V - - - -Weldable electrodes dia. mm up to 3.25 up to 4.0 up to 4.0 up to 4.0Setting range TIG 230 V A / V - 5-150A / 10.2-16.0V 5-180A / 10.2-17.2V 5-180A / 10.2-17.2VSetting range TIG 400 V A / V - - - -Setting Steps inf. variable inf. variable inf. variable inf. variableNo-load voltage V max. 85 max. 85 max. 85 max. 85Welding current at 100% DC (25/40)°C A - / 80 - / 115 - / 130 - / 130Welding current at 60% DC (25/40)°C A - / 110 - / 135 - / 150 - / 150Duty cycle at max. current (25/40)°C % - / 30 - / 40 - / 30 - / 30Mains (table values valid for:) Electrode Electrode TIG TIGMains voltage V 230 230 230 230Mains frequency Hz 50 / 60 50 / 60 50 / 60 50 / 60Mains fusing 230V / 400V (time-lag/C) A 16 16 16 16Input power S1 (100%) kVA 2.90 4.30 3.30 3.30Input power S1 (at max I2) kVA 5.60 6.10 5.10 5.10Mains current input (100%) A 12.4 18.6 14.2 14.2Mains current input (at max I2) A 24.2 26.6 22.3 22.3Power factor (max I2) cos phi 0.99 0.99 0.99 0.99Power supply cable mm◊ 3x1.5 3x2.5 3x2.5 3x2.5Mains plug (230/400V) shock-proof shock-proof shock-proof shock-proofUnitProtection class (IEC 529) IP 23 23 23 23Insulation class F F F FCooling method F F F FNoise emission (EN 60974-1) dB(a) <70 <70 <70 <70Standard EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1Identification CE , S CE , S CE , S CE , SVolume & weightVolume appr. (LxWxH) mm 337x130x211 337x130x211 337x130x211 337x130x211Weight kg 4.5 5.25 5.75 6.5Order number 105.0140.0 105.0150.0 105.0180.0 105.0185.0Technical equipmentWelding current DC / AC X / - X / - X / - X / -Copper winding X X X XInverter technology X X X XSinus Power Management SPM - - - -Remote controllable - - X XHotstart / Arc force / Anti stick X / X / X X / X / X X / X / X X / X / XIgnition: Contact / high frequency - X / - X / - X / XGas management - - X X2-stroke / 4-stroke - / - - / - X / X X / XUp-slope / Down-slope - / - - / - X / X X / X2nd program current / end crater current - / - - / - X / X X / X

Electrode and TIG welding

MIG-MAG welding

Model M 2020 M 2040 M 2060 M 2080Welding range A/V 30-140 / 15.5-21 25-170 / 15.2-22.5 25-210 / 15.2-24.5 30-230 / 15.5-25.5Max. no-load voltage V 36.8 34.9 36.9 32.6Voltage setting Steps 6 6 6 7Duty cycle at max. current (25/40°C) % 25/15 25/15 25/15 30/20Welding current 100%DC (25/40°C) A 70/55 90/70 105/85 140/115Weldable wires steel Ø mm 0.6-0.8 0.6-0.8 0.6-1.0 0.6-1.0Weldable wires aluminium dia. mm 1.0 1.0 1.0-1.2 1.0-1.2Wire feed rate m/min 1 - 23 1 - 23 1 - 23 1 - 23Mains voltage V 1~230 1~230 / 2~400 1~230 / 2~400 3~400Mains frequency Hz 50 / 60 50 / 60 50 / 60 50 / 60Mains fusing (time-lag/C) A 16 16 16 16Max. power consumption S1 (230V) kVA 3.7 3.8 5.0 -Max. input power S1 (400V) kVA - 5.2 6.4 6.8Input power S1 100% (230V) kVA 0.8 - - -Input power S1 100% (400V) kVA - 1.2 1.8 2.3Max. mains current input (230V) A 16.3 16.4 21.6 -Max. mains current input (400V) A - 13 16 9.8Current input I1 100% (230V) A 3.6 - - -Current input I1 100% (400V) A - 3.1 4.4 3.3Power factor cos j 0.85 (140A) 0.84 (170A) 0.89 (210A) 0.89 (230A)Protection class (IEC 529) IP 23 23 23 23Insulation class F F F F FCooling method F F F F FNoise emission dB(A) <70 <70 <70 <70Standard EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1Identification CE, S CE, S CE, S CE, S Ground power source (LxWxH) mm 870x390x610 870x390x610 870x390x610 870x390x610Ground wire feed case (LxWwH mm - - - -Power source weight kg 47 51 55 57Weight water cooling (filled) kg - - - -Weight wire feed case kg - - - -Feed unit Rolls 2 2 2 2Set wire diameter mm 0.6 / 0.8 0.6 / 0.8 0.6 / 0.8 0.8 / 1.0Torch type gas-cooled system ML 1500 ML 1500 ML 1500 ML 2500Torch type water-cooled system - - - -Ground cable - - - -Cooling system (only for water cooling)Standard cooling power (1l/min) kW - - - -Maximum pressure pmax (bar) - - - -Pump - - - -

73

ISI 5 CL HANDY-TIG 210 DC HANDY-TIG 210 AC/DC

3-140A / 20.1-25.6V 3-160A / 20.1-26.4V 3-160A / 20.1-26.4V3-200A / 20.1-28.8V - -

up to 5.0 up to 2.4 up to 3.23-140A / 10.1-15.6V 3-180A / 10.1-17.2V 3-180A / 10.1-17.2V3-220A / 10.1-18.8V - -

inf. variable inf. variable inf. variable80 80.00 85.00

180/150 110/80 110/80200/170 135/100 135/10060/55 30/15 40/25

(Electrode) (TIG) (TIG)1~230 / 3~400 1~230 1~230

50 / 60 50 / 60 50 / 6016 16 165.9 - 1.50 1.508.3 - 3.90 4.308.5 - 6.3 6.312.0 - 16.8 18.40.89 1.0 1.0

5x2.5 3x1.5 3x1.5shock-proof / CEE 16 shock-proof shock-proof

23 23 23F F FF F F

<70 <70 <70EN 60974-1 EN 60974-1 EN 60974-1

CE , S CE , S CE , S

370x210x295 350x138x320 430x138x32016 8.3 11.1

115.0051.0 254.0210.0 254.1210.0

X / - X / - X / XX X XX X X- - X XX X X

X / X / X X / X / X X / X / XX / - X / X X / X

- X X- X / X X / X- X / X X / X- X / X X / X X / X

M 2090 M 2095 M 3050 M 3070 M 3030 automotive30-290 / 15.5-28.5 25-350 / 15.3-31.5 25 - 350 / 15.3 - 31.5 30 - 400 / 15.5 - 34 30 - 260 / (11.4) 15.5 - 27

37.2 42 42 48 3412 24 24 24 41 Digastep

30/20 30/20 45/30 45/30 45/35160/135 185/160 k.A./210 k.A./240 180/1600.6-1.2 0.6-1.2 0.6 - 1.6 0.6 - 1.6 0.6 - 1.21.0-1.2 1.0-1.6 1.0 - 1.6 1.0 - 1.6 1.0 - 1.21 - 25 1 - 25 0.1 - 25 0.1 - 25 0.1 - 253~400 3~400 3~400 3~400 3~40050 / 60 50 / 60 50/60 50/60 50/60

16 25 25 35 16- - - - -

10.8 14.9 15.4 20 9.7- - - - -

2.8 4.5 6.7 8.5 5- - - - -

15.6 21.5 22.3 28.8 14- - - - -

4.1 6.5 9.7 12.2 7.20.89 (290A) 0.89 (350A) 0.89 (350A) 0.87 (400A) 0.87 (260A)

23 23 23 23 23F F F F FF F F F F

<70 <70 <70 <70 <70EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1

CE, S CE, S CE,S CE,S CE,S870x390x610 870x390x610 945 x 425 x 720 945 x 425 x 720 945 x 425 x 720

- - 560 x 190 x 435 560 x 190 x 435 -67 94 109 126 108.5- - 10.5 10.5 -- - 17 17 -4 4 4 4 4

0.8 / 1.0 0.8 / 1.0 1.0 / 1.2 1.0 / 1.2 0.8 / 1.0 aluminiumML 2500 ML 3600 ML 3600 ML 3600 ML 2400 PM

- - MW 5500 MW 5500 -- - 50 mm2, 4 m 50 mm2, 4 m 35 mm2, 4 m

- - 1.1 1.1 -- - 3.5 3.5 -- - Centrifugal pump Centrifugal pump -

HT 180 AC/ DC

20-150A-

up to 4.03-180A

-inf. variable

70k.A. / 110 Ak.A. / 140 A

k.A./ 35%TIG

1~23050 / 60

16

1,03x1.5

shock-proof

23FF

<70EN 60974-1

CE , S

480x185x32613

250.0180.0

X/XXX

XX / X / X

X / XX

X / XX / X

CL 4P-F CL 5P-F

20-130A / 20.8-25.2V 25-120A / 21-24.8V70-175A / 22.8-27.0V 45-200A / 21.8-28V

up to 4.0 up to 5.0- --- -11 inf. variable

48 - 60 48 -60130/110 150/125175/145 200/17060/40 60/40

(Electrode) (Electrode)1~230 / 2~400 1~230 / 2~400

50 / 60 50 / 6016 / 25 16 / 25

5.6 5.58.8 8.813.9 13.822.0 22.0

0.71 (175A) 0.72 (200A)5x2.5 5x2.5

shock-proof / CEE 16 shock-proof / CEE 16

23 23F FF F

<70 <70EN 60974-1 EN 60974-1

CE CE

380x250x400 450x310x44031 49

106.5005.0 106.5007.0

- / X - / XX X-- -- --- -

- / - / - - / - / -- -- --- -- -- -

MIG-brazing

74

Plasma cutting

Model A 1700 and CuSi A 2200 and CuSiWelding MIG / MAG TIG Electrode MIG / MAG TIG ElectrodeWelding range A/V 35-170 / 15.7-22.5 5-150 / 10.2-16 25-150 / 21-26 35-220 / 15.7-25.0 5-200 / 10.2-18 25-200 / 21-28Max. no-load voltage V / DC 60 60Power setting inf. variable inf. variableCharacteristic tendency constant falling falling constant falling fallingWelding current at 100% DC (40°C) A 100 110 100 150 150 100Welding current at 60% DC (40°C) A 120 130 120 170 170 120Duty cycle at max. current (40°C) % 25 35 30 15 35 30Weldable wires steel dia. mm 0.6-0.8 - - 0.6-1.0 - -Weldable wires aluminium dia. mm 1.0 - - 1.0 - 1.2 - -Wire feed rate m/min 1 - 25 - - 1 - 25 - -MainsMains voltage V 1 Ph 230 ± 10% 1 Ph 230 ± 10%Mains frequency Hz 50 / 60 50 / 60Mains fusing (time-lag/C) A 16 16 / 25Input power S1 100% kVA 2.6 2.1 3.2 4.4 3.2 5.3Input power S1 60% kVA 3.3 2.7 4.0 5.1 3.9 6.2Input power S1 at max. current kVA 5.2 3.2 5.3 7.4 4.8 7.4Mains current input I1 100% A 11.2 9.3 14.1 19 14 23Mains current input I1 60% A 14.2 11.6 17.6 22 17 27Mains current input I1 at max. current A 22.6 14.1 23 32 21 32Power factor (at max. current I2) cos phi 0.98 0.98Mains cable mm2 3 x 2.5 3 x 4Mains plug shock-proof shock-proof / CEE 32UnitProtection class (IEC 529) IP 23 23Insulation class F FCooling method F FNoise emission dB(A) <70 <70Standard EN 60974-1 EN 60974-1Identification CE, S CE, SWeights and measurementsPower source measurements (LxWxH) mm 590x280x460 590x280x460Power source weight kg 19.2 20.4Feed unit Rolls 2 - - 2 - -Set wire diameter mm 0.8 - 1.0 - - 0.8 - 1.0 - -Torch type /Electrode holder ML 1500, 4m * WLT 17 EA, 4m * E cable 25 mm, 4m ML 2400, 4m * WLT 26 EA, 4m * E cable 25 mm, 4mGround cable 25 mm2, 4m 25 mm2, 4m

* not as standard

MIG-MAG, TIG and electrode welding

Sorry to say that all prices stated here are subject to addition of the statutory rate ofvalue (added) tax - value (added) being the operative word in our case!

Pricing status: July 2006, print status: June 2006Subject to improvement and to the unavoidable possibility of human error.

Model Z 70 Z 110CuttingSetting range cutting current A 22 - 70 22 - 110Cutting current setting inf. variable inf. variableNo-load voltage V 495 495Cutting current at 100% DC (40°C) A 50 60Cutting current at 60% DC (40°C) A 70 82Duty cycle at max. current (40°C) % 60 35MainsMains voltage (50/60Hz) V 3 Ph 400 ± 10% 3 Ph 400 ± 10%Mains frequency Hz 50 / 60 50 / 60Mains fusing (time-lag/C) A 16 32Mains cable mm2 4 x 2.5 4 x 4Mains plug CEE 16 CEE 32Input power S1(at max. I2) kVA 15.9 30.5Mains input power I1 (at max. I2) A 23 44UnitProtection class (IEC 529) IP23 IP23Insulation class F FCooling method F FNoise emission dB(A) <70 <70Standard EN 60974-1 EN 60974-1Identification CE , S CE , SWeights and measurementsMeasurements (LxWxH) mm 650 x 260 x 470 650 x 260 x 470Weight kg 30.5 31.5Standard equipmentTorch type LCT 80 6m LCT 150 6mGround cable 25 mm2, 4 m 25 mm2, 4 mSupplementary dataAir pressure bar 5.5 - 7 5.5 - 7Air consumption l/min 170 200Max. cutting thickness steel mm 22 37Max. cutting thickness aluminium mm 17 27Max. cutting thickness stainless steel mm 18 30Quality cut steel mm 17 32Quality cut aluminium mm 12 22Quality cut stainless steel mm 14 24

75

iQLorch iQ for industry.

Being industry qualified means

exceeding expectations in the highly demanding

industrial sector too. A word of explanation

at the end of this book.

75

76

Just 1 of 82,344 possibilities...

... a mobile S. Built for use byamedium-sized crane producer.3 shifts, 8 welders, 4 nationalities. Fundamental decision:

High-quality impulse seam, perfectly executed after just 3 setings.Plain text operator prompting in the welder’snative language.

Trolley-mounted tocope with a travel distance of over 20 metresin the production hall. Portable: Used daily on the platform for thin

sheet, but for 6 mm thick material below - hence the need foradditional water cooling.

Series production, shift working, repeat accuracy, operating clarity:What every producer has a right toexpect - from the medium-

sized workshop through tothe biggest multinational corporation. 50 % of the systems weproduce are used in industry.

Systems designed for just one purpose: Doing their designated joband delivering a unique standard of quality based on their

performance and durability. Mobile or stationary.With wire feedecase on the crane or at the fixture. Drawing on this wealth of

experience, wewill tailor you a bespoke suit tofit your operation toperfection. iQ for your production.

C P

V S77

MIG-MAG system with synergetic Digastep.Setting the standard in its class.

Digital MIG_MAG intelligence.Unadulterated performance.

TIG inverterResearch and development for TIG welders.

Digital MIG-MAG pulse system.Far better. Far more productive.

79

When you buy a Lorch system, we willprovide you with all the knowledge you need.

Our practical training courses offer

Process knowledgeAdjustment knowledge

System knowledge

On your own premises. Processing your actual orders. 1 or 2 hours are oftenenough for you to gain a solid grounding in the possibilities available to you

and how to use them successfully.

A highly valuable exercise even for the most experienced professional.Talk to your dealer to arrange your practical training course. We consider it a must.

Your share of the costs is 69.- Euros per hour.Needless to say, we will not charge you any travel expenses.

You will never regret it.

Thanks

book of welding 2007

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