Welding Machine PDF

SPECIFICATION
FOR
SYNERGIC MIG / MAG WELDING MACHINE
1.0
APPLICATION
Synergic MIG / MAG welding machine will be used for spatter free and heavy
duty welding of Carbon Steel, Alloy Steel, Stainless Steel, Inconel etc on
continuos duty cycle
2.0
TECHNICAL SPECIFICATION
(i)
Type
(ii)
Shielding medium
(iii)
Output Current range :
10 to 550 A
(iv)
Welding Current
rating at 100% duty
cycle (10 minutes)
at 40 C
440 A (minimum)
(v)
Welding Current
:
rating at 60% duty cycle
(10 minutes) at 40 C
550 A (minimum)
(vi)
Variation of set current
(vii)
Open circuit Voltage
65 v (minimum)
Up to 25m/min
(viii) Wire feed speed
Digital Microprocessor controlled soft-ware

based inverter type power source.
Argon + Co2 gas mixture and / or CO2
< +/- 1%
(ix)
No load Power
Consumption
< 75 W
(x)
Type of Cooling
Forced air cooled
(xi)
Degree of Protection
IP 23
(xii)
Input Supply
415 +/- 10 % Variation, 3 Phase 50 H +/Variation

Page 1 of 6
(xiii) Working Condition
:
a)
b)
c)
3.0
Ambient Temp. Variation 30 to 500 C

Relative Humidity - 95% (maximum)
during rainy season.
Continuous heavy duty welding in dusty
Fabrication Shop
TECHNICAL FEATURES
(i)
Light weight, Trolley Mounted, Sturdy, Compact, rigid and dust proof
construction.
(ii)
Single knob Synergic Control through in built programs. Only base metal,
wire diameter and shielding gas composition will be selected by Welder
and rest all parameters will be automatically selected by the Synergic
control system.
(iii)
Digital display of all parameters.
(iv)
In-built programmes for welding various combinations of base metals like

carbon steels, alloy steels, stainless steels, Inconel etc. & from thin to
heavy joint thickness.
(v)
Warning and operational LED indications for over/under voltage

and over temperature.
(vi)
Hold function to check pre-set and actual major welding parameters after
welding is over.
(vii)
Gas test button to check gas flow rate before welding.
(viii)
Error code display for maintenance purpose (Error diagnostic function).
(ix)
Automatic Arc length correction control to compensate welder's hand

movements.
(x)
Built - in protective system to sense the water flow in the torch and prevent
burning of Torch incase of insufficient /stoppage of water flow.
(xi)
Short circuit and Single phase protection.
(xii)
Auto-Cut off device built -in the power source to prevent use of higher
current than rated capacity at 100% duty cycle in order to avoid burring of
Torch / Components.
(xiii)
Auto-Cut off built-in the power source in case of over heating.
(xiv)
Fitted with built in cooling unit as single unit. The capacity should be
such that the pump will be able to maintain coolant flow rate at a height
of 6-7 m welding height, so that the torch does not get heated beyond
specified limit.
Page 2 of 6
4.0
SCOPE:Standard Synergic MAG welding machine will consist of following items with
Individual price and Identification No.
Power Source with controls as per technical specification and technical features
(i)
(refer clause 2.0 and 3.0)

Cooling Unit :-
(ii)
-
Integral Water Cooling unit suitable to keep the Torch cools during continuous
welding at rated capacity.
The cooling unit should be interfaced with the Power Source so that in case of
interruption in the flow of coolant through cable hose/Torch, no welding can be
done as a precautionary measure.
Accordingly error message should be
indicated on control panel.

Wire Feed Unit:-
(iii)
-
Light weight, compact and rigid wire feeder with 4 all powered and grooved
Roller drive and suitable for continuous smooth wire feeding with wire dia 1.2
mm and 1.6 mm Solid/Flux Cored Wire.
Wire spool mounting arrangement with braking device for national/ international
standard wire spools properly covered or housed inside the wire feed unit to
prevent direct contact from moisture and dirt.
Welding Torch Adaptor should be Euro Connection type.
Digital display of major weld parameters like current, voltage, wire, speed,
programme no w.r.t. material / thickness etc.
Welding Torch :-
(iv)
-
Ergonomically designed Water Cooled Torch fitted with 4.0 m flexible & light to
handle cable hose and Euro connector.
Torch will be fitted with 2/4 step on-off switch and Up/Down switch for finer
adjustment of current, if required, during welding.
Provision for Torch neck swiveling and locking to suit positional welding
welding in difficult areas.
Page 3 of 6
&
(v)
Cables and Hoses :-
Interconnecting cable/hose assembly (15.0 m long) between Power Source

and Wire Feeder Unit.
(vi)
Earthing cable (5.0 m long) with Plug/Connector.
Input cable (10.0 m long) with Plug.
All Cables will be made of Copper
Accessories :-
Pressure regulator and flow meter built-in with unit.
Trolley with Handle for portability of the unit.
Any other accessories as recommended by vendor for better efficiency and

maximum utilization.
(vii)
Tool Kit consisting of Nozzle Cleaner, Alley keys, Plier for cutting wire etc.
Consumables :Following consumables as applicable for offered Torch model should be offered
with Individual price and Identification no.
-
Various gas nozzles, Spatter guard, diffuser, fixing sleeve, insulation ring,
liners, contact nozzle etc.
Offered consumables will be w.r.t. dia 1.2 mm solid wire and dia. 1.6 flux
cored wire..
(viii)
Spares:a)
Complete list of all the components used in the machine, clearly

marked on the schematic diagram of the machine with identified
part nos. for power source, wire feeds, cooling unit & torch.
Page 4 of 6
b)
Individual price of all components (with identification no.) as

mentioned in (a) above should be given in price bid.
5.0
Five sets of operation and maintenance manuals consisting of following

documents: (i)
Operation and Instructions.
(ii)
Maintenance Instructions.
(iii)
Do's and Don't' s.
(iv)
Assembly diagrams of Power Source and wire feeder with identification

nos.
(v)
Split diagrams of welding Torch with identification nos.
(vi)
Electrical and electronic circuit diagrams, including PCB's with wire nos.
(vii)
Wirings diagrams with wire nos.
(viii)
Trouble shooting and remedies.
(ix)
Details of in-built programs.
(x)
Complete list of spares with identification nos., make, model rating & price
of all the items.
6.0
Commissioning and trials at BHEL works by vendor.
7.0
3 days Training to operational and maintenance personnel at BHEL works.
8.0
3 years guarantee for smooth and trouble free working after commissioning.
9.0
After Sales Service:9.1
Prompt after sales service during and after expiry of guarantee period and
response time should not be more than 48 hours.
9.2
Vendor has to furnish the details of the Indian agent & contact of the
nearest service centre for reporting machine break down.
10.0
IMPORTANT NOTE:10.1
Offer should be complete, point wise as per specification, along with

complete supporting technical details, leaflets of offered model for
technical assessment of the offer.
10.2
Offered scope should be complete and price to be given individual items

as per scope.
Page 5 of 6
10.3
Spares availability to be ensured by vendor for at least 10 years for the

offered model.
11.0 QUALIFICATION CRIETERION:

Offer of only those vendors will be considered who have supplied minimum 10
nos. MIG / MAG Welding Machines of this rating or of higher rating and such machines
must be working satisfactorily for the last 5 years from the date of opening of tender).
Along with their offer vendor must submit list of such customers with their address / email address / phone nos., year of commissioning alongwith model and broad
specifications of the machines supplied to them. Vendor should also submit copy of
commissioning certificates of these machines from their customers.
Page 6 of 6

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SPECIFICATION

Output Current range :

Variation of set current

Open circuit Voltage

(viii) Wire feed speed

Digital Microprocessor controlled soft-ware

Forced air cooled

415 +/- 10 % Variation, 3 Phase 50 H +/Variation

(xiii) Working Condition

Ambient Temp. Variation 30 to 500 C

Digital display of all parameters.

In-built programmes for welding various combinations of base metals like

Warning and operational LED indications for over/under voltage

Gas test button to check gas flow rate before welding.

Error code display for maintenance purpose (Error diagnostic function).

Automatic Arc length correction control to compensate welder's hand

Short circuit and Single phase protection.

Auto-Cut off built-in the power source in case of over heating.

(refer clause 2.0 and 3.0)

Accordingly error message should be

indicated on control panel.

Welding Torch Adaptor should be Euro Connection type.

Cables and Hoses :-

Interconnecting cable/hose assembly (15.0 m long) between Power Source

Earthing cable (5.0 m long) with Plug/Connector.

Input cable (10.0 m long) with Plug.

All Cables will be made of Copper

Pressure regulator and flow meter built-in with unit.

Trolley with Handle for portability of the unit.

Any other accessories as recommended by vendor for better efficiency and

Complete list of all the components used in the machine, clearly

Individual price of all components (with identification no.) as

Five sets of operation and maintenance manuals consisting of following

Operation and Instructions.

Do's and Don't' s.

Assembly diagrams of Power Source and wire feeder with identification

Split diagrams of welding Torch with identification nos.

Wirings diagrams with wire nos.

Trouble shooting and remedies.

Details of in-built programs.

Commissioning and trials at BHEL works by vendor.

3 days Training to operational and maintenance personnel at BHEL works.

After Sales Service:9.1

Offer should be complete, point wise as per specification, along with

Offered scope should be complete and price to be given individual items

Spares availability to be ensured by vendor for at least 10 years for the

11.0 QUALIFICATION CRIETERION:

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