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MAJORJUNIORMIGLIGHTECO class.MIG/MAGweldinginstallations.Economicaland rugged.
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SAF MIG/MAG welding installations are split between three classes of products with specific characteristics and technical advantages best suited to the requirements of various users.These three categories are described below with the SAF installations in each category (see table and diagram below).
250 A1.0 mm
EXPERT
EASY
ECO
350 A1.2 mm
500 A1.6 mm
MAJOR
200 Zn
OPTIMAG500 S
OPTIMAG400 S
OPTIMAG300 S
SAFMIG330 TRi
OPTIPULS
SAFMIG480 TRi
MAJOR
300BL/300S
MAJOR
400BL/400S
JUNIOR203
JUNIOR283
JUNIOR
323/323S
JUNIOR
403/403S
MIGLIGHT
MAJOR500S
Current and wire diameter
Transistortechnology
EXPERT
EASY
ECO
Diodetechnology
Thyristortechnology
Comparative positions of MIG/MAG installations.
MIG/MAG welding installations
SAF expertise is visible and accessible to the welder with the aim of covering all applications.
SAF expertise is made automaticallyavailable to the welder for greaterease of use.
SAF experience and know-how arecombined for the best "price/performance" trade-off.
Occasional welding.Alternative offer (higher or lower duty cycle).
Metalworkers. Craftsmen. Automotivebodywork. Thin sheet metalwork.Ordinary pressure vessels.Small unit-welding shops.
MIG EXPERTQuality andtechnology
MIG EASYSimplicity andproductivity
MIG ECOEconomicaland rugged
Class Concept Applications Activity sectors
High-precision welding for state of the art applications in aluminium and stainless steel.
Intensive welding in all applicationsto non-alloyed steel, stainless steeland aluminium.Even greater productivity with flux-cored wires.
Stainless steel and aluminium pressurevessels.Rolling stock. Shipbuilding.Automotive. Training centres.Chemical and agro-foodstuffs industries.
All pressure vessels.Structural steelwork.Unit-welding shops.Sheet metalwork.Civil engineering plant.Agricultural machinery.
MAJOR
200 Zn
MAJOR
300BL/300S
MAJOR
400BL/400S
JUNIOR203
JUNIOR283
JUNIOR
323/323S
JUNIOR
403/403S
MIGLIGHT
MAJOR500S
3
ECO Class
1145
-20
1145
-62
1145
-53
Q-1
311-
69
1145
-24 11
45-2
7
0951
-53
2238
-02
2705
-26
An alternative offer for two ranges of power suppliesMAJOR : a flexible offer, with a wide choice of options(except for the MAJOR 200 Zn which is specifically for thin sheet metalwork):• built-in wire feed unit (MAJOR BL) or remote wire
feed unit (MAJOR S), • voltage/current/wire feed rate read-out,• liquid (water) cooled torch,• PROMIG range (241/341/441) torch.Excellent performance and power for all intensiveworkshop welding tasks:• duty cycle 60%.
JUNIOR : single offer, with no options and ready for use (just connect the PROMIG torch):• built-in 2-roller wire feed unit
(JUNIOR S with remote wire feed unit).Good welding performance is guaranteed by the flexibility and quality of JUNIOR power supplies:• duty cycle 35%.
MIGLIGHT :SAF's portablesingle-phase MIGinstallation.
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ECO Class: MIGLIGHT, JUNIOR 203, 283, 323
JUNIOR 2030.8 mm
Five MIG/MAG welding installations for all assembly applications, using solid wire of non-alloyed steel, stainless steel and aluminium and flux-cored wire.Thin sheet metalwork, automobile bodywork, locksmiths, craftsmen, routine repair and maintenance tasks and unit-welding SMEs.
1124
-24
Craftsmen and metalworkers SMEs
Repairs
• Ideal for thinsheet metal.
• Routine repairand maintenancetasks.
• Polarity can be reversedfor welding with flux-coredwire.
• Continuous, intermittent or spot welding.
• Easy to use with all thecontrols on the front paneland a table to help in choosing settings.
• Unit-welding.• Small pressure
vessels.• Compact
or separate version for thesemultipurpose,easy to use power supplies.
• Clearly laid-outand functionalfront panel for simplicity of use.
• Wide choice of options to caterfor a wider rangeof applications.
230/400 V
THREE-PHASE
JUNIOR 3231.2 mm
0951
-53
Multivoltage
THREE-PHASE
JUNIOR 2831.0 mm
Usual wire diameter.
1124
-27
MIGLIGHT0.8 mm
2705
-26
SINGLE-PHASE
230 V
JUNIOR 4031.2 mm
2000
-314
230/400 V
THREE-PHASE230/400 V
THREE-PHASE
• 230 V single-phase.Welds non-alloyed steel without gas, using SAFUNI 310 1.0 mmdiameter flux-cored wire. Ideal for outdoor work.
Compact and portable:• the MIGLIGHT is delivered ready to use as a single package,
complete with a MIGLIGHT 141 torch and all the necessaryaccessories, together with a spool of SAFUNI 310 1.0 mm diameter flux-cored wire for welding without gas.
Simple to use:• all unit-welding tasks on:
- thin sheet metal,- galvanized sheet metal,- aluminium (0.8 mm diameter solid wire).
5
and 403
1124
-27
� Europeanstandard quick-releasetorch connector.
� Built-in or separate (S version) wire feed unit(two rollers).
� Polarityreversingswitch.
� Quick and simple selection of weldingcycle:• continuous welding
("two stage"),• "spot" welding,• "intermittent" welding.
� Settingstable.
� Wire feed rate adjustment.
� On/offswitch.
MIGLIGHT JUNIOR JUNIOR JUNIOR JUNIOR 203 283 323 / 323S 403 / 403S
Primary specifications 230 V 50 Hz 230/400 V 50/60 Hz 230/400 V 50/60 Hz 230/400 V 50/60 Hz 230/400 V 50/60 Hz Power supply single phase three-phase three-phase three-phase three-phase
Maximum current 21 A 8.5 A (400 V) 15.5 A (400 V) 27 A (400 V) 25 A (400 V)14.8 A (230 V) 27 A (230 V) 42 A (230 V) 43 A (230 V)
Secondary specifications
No load voltage 53 V 33 V 41 V 51 V 46 V
Welding current 35 A to 115 A 27 A to 165 A 50 A to 240 A 40 A to 320 A 40 A to 360 A
Duty cycle (40 °C) at 100 % 55 A 100 A 145 A 200 A 250 A
at 60 % 65 A 130 A 185 A 230 A 320 A
at 35 % 115 A (20 %) 165 A 240 A 320 A 360 A
Welding wires Steel/SS 0.6 and 0.8 mm 0.6 to 1.0 mm 0.6 to 1.2 mm 0.8 to 1.2 mm 0.8 to 1.6 mmAluminium 1.0 mm 1.0 mm 1.0 and 1.2 mm 1.0 and 1.2 mm 0.8 to 1.6 mmFlux-cored 1.0 mm 1.0 mm 1.0 and 1.2 mm 1.0 and 1.2 mm 0.8 to 1.6 mm
Wire feed unit
Number of rollers 2 2 2 2 2
Wire feed rate 0.8 to 21.5 m/min 1 to 21 m/min 1 to 21 m/min 1 to 18 m/min 1 to 20 m/min
Welding cycles 2 S 2 S - spot - interm. 2 S - spot - interm. 2 S - spot - interm. 2 S/4 S - spot - interm.
Dimensional specifications
Dimensions (L x W x H) 480 x 330 x 350 mm 800 x 510 x 690 mm 800 x 510 x 690 mm 850 x 495 x 735 mm 970 x 550 x 900 mm
Net weight 27 kg 53 kg 60 kg 90 kg (323) 148 kg (403)110 kg (323 S) 168 kg ( 403 S)
Protection IP 22 IP 21 IP 21 IP 23 IP 23
Standards EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1
ECO Class: MAJOR 200 Zn, 300 BL/S, 400 B
MIG/MAG welding installations with built-in or separate 2-roller or 4-roller wire feedunit, for all assembly applications using solid wire of non-alloyed steel, stainless steel and aluminium and flux-cored wires.
Excellent welding performanceis combined with:• new arc striking system:
- more gentle,- less spatter,- no splintering of the wire.
• multipurpose applicationsfrom automobile bodywork(MAJOR 200 Zn) to themost diverse tasks in allfields of manufacture,
• choice and modularity of equipment to suit the needs of users,
• intensive use: 60% duty cycle,
• auto-diagnostics,• thermal safety cut-out
in the event of an overload,• electronically controlled
wire feed rate,• polarity can be reversed
for use with all flux-coredwires,
• integral wire feed unit(MAJOR BL) or remotewire feed unit (MAJOR S)with four rollers,
• digital read-out of weldingparameters (as standard oroptional, as appropriate),
• air-cooled or water-cooled torch,
• improved comfort and safety.
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MAJOR 200 Zn
• Simple to use, the MAJOR 200 Zn is ideal for welding galvanized sheetmetal (using SAFDUAL Zn 1.0 mmflux-cored wire) and thin sheet metal(0.6 mm wire).Specific options for automobilebodyshops.(dent remover, shrink heating).
MAJOR 300 BL/S
• Built-in or remote wire feed unit. • Cylinder trolley and large diameter
wheels.
Q-1
311-
69
1145
-53
Thin sheet
metal special Accuracy for small
thicknesses
MAJOR 400 BL/S
• Integral or remote wire feed unit.• Cylinder trolley and large diameter
wheels.• Easily converts to water-cooled use
by incorporating water-cooling unitcompartment.
MAJOR 500 S
• Higher welding power, with currents up to 500 A.
• 4-roller wire feed.• Space for water-cooling unit.• Cylinder trolley and large diameter
wheels.
1145
-62
1145
-20
Multipurpose Intensive welding with
flux-cored wires
0.8 mm 1.0 mm
1.2 - 1.6 mm1.2 mm
Usual wire diameter.
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L/S and 500 S
� Separate DV344-roller wirefeed unit for 300 S,400 S and 500 Sversions,lightweight andcompactwith fast wire feed.Tachogeneratorspeed control.
� Safe to use:• protected against
overloads andstopping of fan.
� Polarityreversing switch.
1145
-20
� New arc striking process(on MAJOR 400 and 500),• reduced speed,• minimum self-inductance
level.� Digital settingand pre-settingas standard on MAJOR 500, optionalon MAJOR 300 and MAJOR 400.
� Wide choiceof versions.
� Disengageablecooling unit.
MAJOR MAJOR MAJOR MAJOR200 Zn 300 BL and 300S 400 BL and 400S 500S
Primary specifications 230/400 V 50/60 Hz 230/400 V 50 Hz 230/400 V 50/60 Hz 230/400 V 50/60 HzPower supply three-phase three-phase three-phase three-phase
Maximum current 7.3 A (400 V) 15.7 A 29 A (400 V) 39 A (400 V)13.5 A (230 V) 50 A (230 V) 68 A (230 V)
Secondary specifications
No load voltage 11 to 28 V 16.5 to 38 V 18.6 to 51 V 14 to 53 V
Welding current 10 A to 160 A 20 A to 270 A 40 A to 400 A 40 A to 500 A
Duty cycle (40 °C) at 100 % 135 A - 270 A 350 Aat 60 % 150 A 270 A 330 A 450 Aat 35 % 160 A (45 %) - 400 A 500 A (45 %)
Welding wires Steel/SS 0.6 and 0.8 mm 0.8 to 1.2 mm 0.8 to 1.6 mm 0.8 to 1.6 mmAluminium 1.0 mm 1.0 and 1.2 mm 1.0 to 1.6 mm 1.0 to 2.4 mmFlux-cored 1.0 and 1.2 mm 1.0 and 1.2 mm 1.0 to 1.6 mm 1.0 to 1.6 mm
Wire feed unit
Number of rollers 2 4 2 4
Wire feed rate 1 to 11.5 m/min 0 to 20 m/min 0 to 20 m/min 0 to 20 m/min
Welding cycles 2 S - spot - interm. 2 S/4 S - spot 2 S/4 S - spot 2 S/4 S
Dimensional specifications
Dimensions (W x L x H) 875 x 440 x 780 mm 890 x 500 x 820 mm 1 114 x 530 x 955 mm 1075 x 630 x 1075 mm
Net weight 72 kg 115 kg 140 kg (400 BL) - 152 kg (400 S) 212 kg (air) - 228 kg (water)
Protection IP 23 IP 23 IP 23 IP 23
Standards EN 60974-1 EN 60974-1 EN 60974-1 EN 60974-1
Standard offer code VB 05-100 VB 02-100 VB 03-1003 m torch package 9160-0690 9160-0683 9160-06854 m torch package - 9160-0684 9160-0686Standard equipment • 2 m primary cable • 3 m primary cable • 3 m primary cable
with 230 V plug • 3 m secondary cable • 3 m secondary cable• secondary plug with earth clamp with earth clamp
with earth clamp • gas hose • gas hose• MIGLIGHT 141 torch • PROMIG 181 torch • PROMIG 241 torch• 5 kg spool of SAFUNI 310 • plastic spool adapter • plastic spool adapter
flux-cored wire for welding without gas
• wheels kitAdd-ons and options • replaceable parts - -
kit 9149-0516
8
MIGLIGHT JUNIOR 203 JUNIOR 283
ECO Class: ordering information
JUNIOR range compact or separate
MAJOR range compact version
35%dutycycle
Standard offer code VC 02-110 VF 02-100 VF 04-1003 m torch package 9160-0638 - 9160-0640* 9160-1500 9160-15054 m torch package 9160-0639 9160-1501 9160-1506Standard equipment • 5 m primary cable • 5 m primary cable • 5 m primary cable
• secondary cable with earth clamp • 50 mm2 secondary cable • 50 mm2 secondary cable• PROMIG 181 torch with earth clamp with earth clamp• gas hose • gas hose • gas hose• spot welding nozzle • PROMIG 241 torch • PROMIG 241 torchAdditional with bodyshop special version: • plastic spool adapter • plastic spool adapter• SAFDUAL Zn 1.0• 0.8-1.6 flux-cored wire roller• smooth contact tube• wear conduit
Add-ons and options • dent remover • digital voltage/current/wire feed • digital voltage/current/wire feed cat. N° 9160-0500 rate read-out, auto-diagnostics rate read-out, auto-diagnostics
• shrink heating cat. N° 9160-1060 cat. N° 9160-1060cat. N° 9160-0460 • separate wire feed unit: • separate wire feed unit:
cat. N° 9160-0389 (DV32) cat. N° 9160-0389 (DV32)cat. N° 9160-0387 (DV34) cat. N° 9160-0387 (DV34)
60%dutycycle
Standard offer code VB 04-100 VB 04-200 VE 01-200 VE 01-201Packages
3 m torch 9160-0609 - 9160-0624 -4 m torch 9160-0610 - 9160-0625 -3 m torch - 10 m harness - 9160-0611 - 9160-06264 m torch - 10 m harness - 9160-0612 - 9160-0627
Standard equipment • 3 m primary cable • 3 m primary cable • 3 m primary cable • 3 m primary cable• 3 m secondary cable • 3 m secondary cable • 3 m secondary cable • 3 m secondary cable
with earth clamp with earth clamp with earth clamp with earth clamp• gas hose • gas hose • gas hose • gas hose• PROMIG 341 torch • remote wire feed unit • PROMIG 341 torch • remote wire feed unit• plastic spool adapter with 10 m harness • plastic spool adapter with 10 m harness
• PROMIG 341 torch • PROMIG 341 torch• plastic spool adapter • plastic spool adapter
Add-ons and options - • wire feed unit trolley - • wire feed unit trolley9160-0196 9160-0196
JUNIOR 323
MAJOR 200 Zn MAJOR 300 BL MAJOR 400 BL
JUNIOR 323S JUNIOR 403 JUNIOR 403S
* multi-voltage version.
EASYFLOW pressure regulatorcat. N° 0961-0930
Air-cooled PROMIG 341 - 3 m 9149-2515 341 - 3 m 9149-2515 441 - 3 m 9149-2521341 - 4 m 9149-2516 341 - 4 m 9149-2516 441 - 3 m 9149-2522
Water-cooled PROMIG - 341 W - 3 m 9149-2533 441 W - 3 m 9149-2539- 341 W - 4 m 9149-2534 441 W - 3 m 9149-2540
Package with 3 m torch and 2 m harness - - 9160-1351 9160-1355Package with 4 m torch and 2 m harness - - 9160-1352 9160-1356Package with 3 m torch and 10 m harness 9160-1510 9160-1515 9160-1353 9160-1357Package with 4 m torch and 10 m harness 9160-1511 9160-1516 9160-1354 9160-1358
Water-cooling unit compartmentCat. N° 9160-1062
Water cooling-unitCat. N° 9157-0406
Pivoting standCat. N° 9160-1063
Digital read-outCat. N° 0961-0930
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DV 32 - air - 10 m length - 50 mm2
Cat. N° 9160-0389 (2 rollers)
DV 34 - air - 2 m length - 95 mm2
Cat. N° 9160-0390
DV 34 - air - 10 m length - 70 mm2
Cat. N° 9160-0387
DV 34 - air - 10 m length - 95 mm2
Cat. N° 9160-0391
DV 34 - air - 2 m length - 70 mm2
sheathed - Cat. N° 9160-0384
DV 34 - air - 5 m length - 70 mm2
sheathed - Cat. N° 9160-0385
DV 34 - air - 10 m length - 70 mm2
sheathed - Cat. N° 9160-0386
DV 34 - water - 2 m length - 95 mm2
sheathed - Cat. N° 9160-0397
DV 34 - water - 10 m length - 95 mm2
sheathed - Cat. N° 9160-0388
Trolley Cat. N° 9160-0196
Spool coverCat. N° 9160-0084
Slinging armCat. N° 9160-1061
Water kitCat. N° 9160-0194
Removable remote control box Cat. N° 9160-0145
Stationary remote control boxCat. N° 9160-1067
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MAJOR 300S MAJOR 400SMAJOR 500S
AIR WATER
Basic catalogue number (power supply only) 9160-0377 9160-0381 9160-0368 9160-0369*
Standard offer code VF03 100 VF05 100 VF01 100 VF01 200
MAJOR range with separate wirefeed unit• Choose your own
installations.
• Ready to use package.
Package comprises power supply, torch and DV34 4-roller wire feed unit with a non-sheathed harness for the air-cooled versions and a sheathed harness for the water-cooled versions (except 300 S, DV32 2-roller wire feed unit, non-sheathed harness).
AIR-cooledversionrecommendedAIR-cooledversion possible
WATER-cooled versionrecommended
OptionKEY
as standard
as standard
* multi-voltage version.
or MAJOR300 BL
or MAJOR400 BL
multivoltageversion
or MAJOR400 BL
or MAJOR400 BL
10
Pivoting standFixes to the top of the power supply using the two lifting rings.Receives and swivels the DV34wire feed unit with or without its trolley.Cat. N° 9160-1063
Liquid-cooling unit for the torchLiquid-cooling unit for effectivecooling of the welding torch.Cat. N° 9157-0406.• integral flowrate cut-out,• thermal safety cut-out,• cooling capacity : 1.5 kW,• flowrate : 3 l/min (4.2 bars),• delivered with a 5-litre
tin of LIQUISAF.Mounts in and connects easily to all power supplies with a water-cooling compartment.This compartment is included as standard on the MAJOR 500 Sand is an option on the MAJOR 400 S.Cat. N° 9160-1062.
EASYFLOW pressureregulator/flowmeter Drum-type pressure regulator/flowmeter for quick adjustment of shielding gas flowrate in MIG/MAG welding.Seven preset flowrates:0, 12, 15, 18, 20, 22 and 25 l/.min.Cat. N° 0961-0930.
• Powerful wire feed unit, 4-roller mechanism, all grades of wire up to 2.4 mm diameter.
• Tachogenerator speed control from 0 to 20 m/min.
• Rugged and reliable (no electronics).• Minimum overall size
(can be passed through a manhole).• Shipped with different lengths
of harness (see catalogue numbers in selection table).
• Many options (see opposite).
DV34 wire feed unit
Options for MAJORpower supplies
Options for DV34wire feed unit
1145
-45
1145
-39
1145
-44
1145
-31
0111
-09
1145
-70
TrolleyCat. N° 9160-0196
1145
-70
Spool coverCat. N° 9161-0084
1145
-70
Water-cooling kit for wire feed unitTo convert an "air-cooled" wirefeed unit to a "water cooled”unit, supplied with 2 x 10 m of hose. Cat. N° 9160-0194
1124
-04
Slinging armUsed to suspend the wire feedunit. Cat. N° 9160-1061
1124
-06
Remote controlFor remote control of wire feedrate and arc height (voltage).Cat. N° 9160-0145
1185
-06
MIG torches MIG/MAG 3 m 4 mInstallation harness harness
MIGLIGHT 141 MIGLIGHT 9149-0094 -PROMIG 181 MAJOR 200 Zn
JUNIOR 203 9149-2500 9149-2501PROMIG 241 MAJOR 300 BL and 300 S 9149-2506 9149-2507
JUNIOR 283PROMIG 341 MAJOR 400 BL and 400 S (W) 9149-2515 9149-2516
JUNIOR 323 and 323 SPROMIG 341 W MAJOR 400 BL and 400 S (W) 9149-2533 9149-2534PROMIG 441 MAJOR 500 S 9149-2521 9149-2522PROMIG 441 W MAJOR 500 S (W) 9149-2539 9149-2540
11
ECO Class: torches and accessories
The new cylinder with integralpressure regulator valveEasier : save time• Easy to use because of the integral
pressure regulator, the open/close lever and the quick-release connector, your gas is shipped ready to use.
• Perfect ergonomics, its ergonomically designed handle and specially designedhandgrip make holding and rolling the cylinder simplicity itself.
Safer : improved safety• Safe pressure/flowrate because users are
no longer exposed to the high pressure.The gas is directly available atthe operating pressure/flowrate.
• The pressure regulator is totallyprotected by the reinforced polyamide shroud.
• Each time the cylinder is refilled,our technicians apply the rigorousAIR LIQUIDE quality controlchecks.
More economic : reduced consumptionEconomize on your gas, a pressuregauge that is active at all times and a reliable flowrate mean youcan save on gas:• no leaks,• no more cylinders sent back half
full,• no more over-consumption.ALTOP for ALCAL 21 and ATAL 5Agases.
1272
-41
1121
-05
2719
-37
1415
-26
1266
-58
0200
-24
3551
-48
3551
-49
2244
-32
0951
-25
0951
-30
PROMIG Torches
Welder protection
Liquid crystal helmetsEUROLUX F• fixed shade 11Cat. N° 0082-0484
EUROLUX V• variable shade
9 to 13Cat. N° 0082-0490
NERTALICgauntlets• for everyday
useCat. N° 0007-8087
SAFDUALgauntlets• for intensive
useCat. N° 0007-8077
Welder'sapron• length 900 mm,
width 700 mmCat. N° 0820-8210
ALTOP
Accessories Trolley
SAFCLEANnon-stick• 650 ml aerosolCat. N° 9159-0180
MIG pliers• cleaning
nozzles,unscrewingcontact tubes,cutting wire
Cat. N° 0002-0051
FLOWSAF• measures torch
outlet flowrateCat. N° 0002-0019
WELDYCAR• portable
self-propellingtrolleysfor weldingin all positions
Cat. N° 9130-0100
AZUR : welding fumes extraction system.A wide range of equipment (suction torches, fans, arms and booms, filter units, etc) and made-to-measure solutions for improving welders' working conditions.Consult SAF.
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DISTRIBUTOR’S STAMP
SAF WELDING PRODUCTS LTD - LOW MARCHLONDON ROAD - DAVENTRY - NORTHANTS NN11 4SDTEL. : 01327 705511 - TELEFAX : 01327 701310
SAF - 13-17 RUE D’EPLUCHES95310 SAINT-OUEN L’AUMÔNE - FRANCETEL. : + 33 1 34 21 33 33 - FAX : + 33 1 34 21 31 30
E mail : [email protected] : www.saf-airliquide.com
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