MECHAFIN PushPull Manuel utilisateur
Weldingaccessories- SwissQuality
MECHAFIN AG has the right to make changes to the operating manual without prior notice, which
may be necessitated due to printing errors or potential neglect of the information contained the-
rein, or further product development. Any changes will then be listed in newer editions.
Operating Instructions for Mechafin PushPull
Operating instructions Intermediate drive PushPull MECHAFIN AG 03 / 2023 1
Content
1. Assessment 2
1.1. EU Declarations of Conformity 2
1.2. Manufacturer's obligations 2
2. Product description 2
2.1. Product description 2
2.2. Intended use 2
2.3. Technical data 3
3. Safety instructions 4
3.1. Essential safety instructions 4
3.2. General safety instructions 4
3.3. Specific hazard instructions 5
3.4. Technical condition 5
3.5. Characterisation 5
4. Delivery contents 5
4.1. Transport 5
5. Function 6
5.1. MIG/MAG welding torch 6
6. Commissioning the intermediate drive 6
6.1. Preparation for welding 7
6.2. Connecting 7
6.3. Introducing wire 8
6.4. Opening/closing the pressure arm 8
6.5. Changing the feed roller 9
6.6. Exchanging the wire guide 9
6.7. Exchanging the wire liner 10
6.8. Coolant (this is only required for liquid-cooled welding torches.) 11
6.9. Setting the shielding gas quantity 11
6.10. Application 11
7. The control unit 12
7.1. Overview 12
7.2. Technical data 12
7.3. Pin assignment 13
7.4. Operation of the control unit 13
7.5. Operation overview 14
7.6. Program modes 16
7.7. Commissioning the intermediate drive with the control unit 20
7.8. Calibration process of the control unit during commissioning 20
7.9. Fastening the control unit 21
7.10. Connecting the intermediate drive for welding 22
7.11. Starting the welding process 23
8. Operation 23
9. Maintenance I Cleaning 24
9.1. General information 24
9.2. Hose pack 24
9.3. Wire liner 24
10. Disassembly and disposal 25
11. Emergency 25
12. Warranty 25
13. Faults and how to remedy them 26
14. Accessories and wear parts 27
15. Length recommendation for the PUSH PULL 28
2Operating instructions Intermediate drive PushPull MECHAFIN AG 03 / 2023
1. Assessment
The MECHAFIN AG intermediate drive is exclusively intended to weld with shielding gas. Welding can
be carried out with inert gases (MIG), or active gases (MAG). The intermediate drive is intended for
industrial and commercial use. It is available as gas or liquid cooled. A cooling unit is required for the
liquid-cooled welding torches. The welding torches should only be operated with original MECHAFIN
AG spare parts.
1.1. EU Declarations of Conformity
In accordance with EC Low-Voltage Directive 73/23/EEC, Appendix 111, we
MECHAFIN AG
Chrummacherstrasse 3
8954 Geroldswil
Switzerland
hereby declare, that the intermediate drive described, on account of its construction and design, as well
as the version that we have put on the market, comply with the EC Directive's relevant essential health
and safety requirements. This declaration will become void if changes are made to the intermediate
drive that have not been agreed with us.
Harmonised standard used:
DIN EN 60 97 4-7 Light arc welding devices; Part 7 Torches
1.2. Manufacturer's obligations
National implementation of the Framework Directive (89/391/EEC), as well as the associated
individual Directives, particularly the Directive on the minimum requirements for health and safety
when contractors use equipment at work (89/655/EEC) as amended, must be observed and adhered
to. The Occupational Health and Safety Act and the Ordinance on Industrial Health and Safety must
be observed. The operator must also ensure that the wire feed system complies with EC Directive EMC
(89/336/EEC) in conjunction with welding devices, and that signal exploitation is installed from the
built-in welding current monitoring system against surface leakages so the power source can switch
off safely.
2. Product description
2.1. Product description
Depending on the design, MECHAFIN AG MIG/MAG welding torches are gas or liquid-cooled. The hose
pack of the intermediate drive is geared towards the respective torch cooling system. All elements form
a functional unit.
2.2. Intended use
Overburdening the intermediate drive or improper use is prohibited. Observing the prescribed operating,
maintenance and servicing conditions is also part of intended use. Wear and damage that can be at-
tributed to overloading or improper use are not covered by the warranty.
Operating instructions Intermediate drive PushPull MECHAFIN AG 03 / 2023 3
2.3. Technical data
General data (operating conditions)
Voltage type: DC voltage
Electrode polarity: usually positive
Wire types: All commercially-available round wires
Guide type: machine-guided
Voltage calculation: 113 V peak value, 141 V peak value
Protection type on the machine side
Connections (EN 60 529): IP3X, IP2X
Shielding gas: C02 or mixed gas M21 according to DIN EN 439
Hose packs:
Standard length L: 5.00m; 10.00m; 15.00 m; 20.00m; 25.00m
Coolant connection: Push-on nipple size NW 5
Cooling unit output: min. 800 to 1000 W
Standard control line: 2-wire
Model-specific data
Item number Cooling Connection for welding wire Wire Ø [mm] Length [m]
119864 Liquid Euro Steel 1.2 5.0
117218 Liquid Euro Steel 1.2 10.0
117219 Liquid Euro Steel 1.2 15.0
117217 Liquid Euro Steel 1.2 20.0
117220 Liquid Euro Steel 1.2 25.0
119915 Liquid Euro Aluminium 1.2 5.0
117215 Liquid Euro Aluminium 1.2 10.0
117216 Liquid Euro Aluminium 1.2 15.0
118458 Gas Euro Steel 1.2 5.0
117208 Gas Euro Steel 1.2 10.0
117209 Gas Euro Steel 1.2 15.0
117210 Gas Euro Steel 1.2 20.0
117211 Gas Euro Steel 1.2 25.0
119916 Gas Euro Aluminium 1.2 5.0
117204 Gas Euro Aluminium 1.2 10.0
117205 Gas Euro Aluminium 1.2 15.0
Attention: these products exclusively concern the PushPull.
The control unit must be ordered separately.
You will find the list with the control units and corresponding parts on page 27.
4Operating instructions Intermediate drive PushPull MECHAFIN AG 03 / 2023
3. Safety instructions
WARNING / CAUTION
A potentially hazardous situation is described here. If this is not reported, serious injuries and material
damage may result.
NOTE
A potential hazard is described here which indicates impaired work results and potential damage to
the equipment.
IMPORTANT
Describes usage tips and other helpful information.
This is not a signal for dangerous or harmful situations.
3.1. Essential safety instructions
This operating manual explains information to the user that is required for flawless and safe operation.
NOTE
No liability will be assumed by MECHAFIN AG If there is any material damage due to disregard of the
operating manual.
3.2. General safety instructions
• The operating manual must be diligently read and followed before work due to commissioning,
operation or transport.
• The operating manual must be provided with the product for reference. The operating manual must be
handed on when the product is passed on.
• The operating manuals of welding components such as welding power sources or wire feeding units
must also be observed.
• For gas cylinder handling, please refer to the gas manufacturer's or supplier's instructions, and
the compressed gas regulation.
• The respective country's accident protection regulations must be observed.
• Operating and maintenance work may only be carried out by specialists. A specialist is a person who,
due to their training, experience, skills and knowledge of relevant standards, can assess work carried
out by third parties and recognise potential hazards.
• Suitable fire protection equipment must be present at the workstation.
Operating instructions Intermediate drive PushPull MECHAFIN AG 03 / 2023 5
3.3. Specific hazard instructions
• Eye, skin and hearing damage may occur during light arc welding! Protective work wear must always
be worn for eye, skin and hearing protection according to the respective country's relevant regulations.
• Metal vapours that occur are very harmful, especially with lead, cadmium, copper and beryllium!
• Adequate ventilation or extraction must be ensured during welding. Specified MAC values (max.
allowable concentration) may not be exceeded.
• Work pieces that have been cleaned with chlorinated solvents or degreased should be rinsed with clear
water, otherwise there is a risk of gasification.
• A greasing bath containing chlorine should not be set up in proximity to the welding area.
• Other hazards may occur when using welding torches such as those due to electric current (power
source, internal circuit), welding spatter as a result of flammable or explosive substances, UV radiation
due to the light arc, smoke and vapours.
• The intermediate drive must always be used when it is closed.
• The housing is made of aluminium and carries the welding voltage. Although it is in the safe low
voltage range, the device must not be operated by pacemaker patients.
• The drive wheels have a strong torque and can injure fingers. Do not reach into the open wheels.
• When working on the intermediate drive, switch the welding unit off if possible.
3.4. Technical condition
• The specified performance data are the maximum determined limit values.
• Any overloading leads to destruction and thus grossly negligent destruction.
• It is forbidden to make physical changes without discussing them with the manufacturer.
• Use suitable protection against weather influences during outdoor use.
3.5. Characterisation
The following information is important for all queries:
• Labelling on connection housing on the machine side
• Visible item numbers or serial numbers
• Production stickers on the housing
4. Delivery contents
All intermediate drives are delivered fully assembled and checked ready for connection and operation.
• Intermediate drive
• Operating manual
NOTE
For order numbers and item numbers of equipment and wear parts, please refer to the order documen-
tation. Check that the equipment parts are correct for initial fitting.
4.1. Transport
The product is always diligently checked and carefully packed before dispatch. However, damage
occurring during transport cannot be excluded.
6Operating instructions Intermediate drive PushPull MECHAFIN AG 03 / 2023
Incoming control
Always check that the delivery contents are complete using the delivery note.
In the event of damage
Always check the delivery contents for damage via a visual check.
In the event of any complaints
If the delivery has been damaged during transport, get in touch with the forwarder immediately. Keep
the damaged packaging and the damaged delivery contents in case they are checked by the forwarder.
Document the damage, preferably with photos.
Packaging for returns
If possible, please use the original packaging and the original packaging material. If you have any
questions about the packaging or transport safety devices, get in touch with the supplier.
Storage in an enclosed room
CAUTION
Material damage
• Coolant that is still in the hose may freeze and damage the hose in the event of frost.
• It must be ensured that coolant is no longer present in the hoses in the event of frost.
Ambient air temperature during transport and storage: - 25°C to + 55°C
Relative humidity: up to 90% at 20°C
5. Function
The MIG/MAG intermediate consists of the following parts:
• Unit (push-pull system)
• Hose pack
• Control unit (plus cable)
5.1. MIG/MAG welding torch
Wires made of steel, aluminium, copper, nickel and stainless steel are conveyed through the welding
system for welding. The wires can be filling wires or solid wires. The light arc and the weld pool are
protected by inert gas (MIG) and active gas (MAG). The wires are conveyed by the contact tips. In this
case, the contact tip transfers the welding current to the wires. The light arc forms between the wire
and workpiece. The welding torches are either gas-cooled or liquid-cooled, and the hose pack has also
been designed accordingly.
6. Commissioning the intermediate drive
DANGER
Risk of injury
In the event of inadvertent start-up, during maintenance, installation or repair work.
Always take the following precautionary measures for the entire duration of the work:
• Pull out mains plug
• Shut off gas supply
• Switch off the power source
A B
Operating instructions Intermediate drive PushPull MECHAFIN AG 03 / 2023 7
6.1. Preparation for welding
Before commissioning, make sure that the liner that matches the wire is inserted (Chapter 6.7).
Please replace if necessary. The wire guide must also fit (Chapter 6.6).
NOTE
New wire liners or plastic wire guides must always be adapted to the hose pack.
Are the correct feed rollers used? If not, proceed according to (Chapter 6.5).
6.2. Connecting
Connect the hose pack of the intermediate drive to your wire feeder with a Euro plug (just like the
welding torch). Connect the two water connections (for the water-cooled intermediate drive) correctly.
Connect the motor / encoder plug with the corresponding connector of your machine.
Connect the welding torch (gas or liquid cooled) to the Euro plug of the intermediate drive.
For the connection of a gas-cooled welding torch, the water connections can be bridged in systems that
are intended for water cooling. This creates a connection between port A water supply (blue) and port
B water return (red). Application only when using a gas-cooled burner.
1
1
8Operating instructions Intermediate drive PushPull MECHAFIN AG 03 / 2023
6.3. Introducing wire
Lay out the intermediate drive with stretched hose as straight as possible. Open the intermediate drive
in order to observe the correct wire feeding process. Place the wire reel in the feeding device of your
welding source. Deburr the cut welding wire with emery cloth or file. If the wire is deburred and reason-
ably straight, it will thread itself. In case of a fault, stop and insert the wire by hand into the wire guide.
NOTE
Deburr the interface on the wire every time the wire is changed.
6.4. Opening/closing the pressure arm
The wire can be extended in idle mode. In special cases you can open/close the pressure arm (dark grey)
manually. To do so, open the housing, unlock the bayonet and pull the slider back.
To open lift the pressure arm (dark grey) at position [1] with a slotted screwdriver.
To close, press the pressure arm down until it locks into place.
1
3
4
2
3
1
2
Operating instructions Intermediate drive PushPull MECHAFIN AG 03 / 2023 9
6.5. Changing the feed roller
Open the pressure arm. Open the fastening screw [1].
Remove the driving sprocket, then pull the feed roller [4] from the sprocket [3]. Then
replace the feed roller and reassemble in reverse order.
6.6. Exchanging the wire guide
Open the Allen screw [1]. Replace the wire guide [2]. For exact positioning, make sure that the notch
[3] is positioned under the Allen screw. Then carefully tighten the Allen screw again.
6.7. Exchanging the wire liner
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