EWM Inverter TIG 150 DC Bedienungsanleitung

EWM HIGHTEC WELDING GmbH

Dr.-Günter - Henle - Straße 8; D-56271 Mündersbach

Phone: +49 (0)2680.181-0; Fax: +49 (0)2680.181-244

Internet: www.ewm.de ; E-mail: [email protected]

Operating instructions

inverter TIG DC welding machines

from 150A – 300A

portable

inverter TIG 200 DC powerSinus

power Cooler

inverter TIG 150 DC

inverter TIG 250 DC

inverter TIG 300 DC

These operating instructions must be read before commissioning!

Failure to do so may be dangerous!

Machines may only be operated by personnel familiar with the appropriate safety regulations!

The machines bear the conformity mark - and thus comply with the

?EC Low Voltage Guideline (73/23/EEC)

?EC EMV Directive (89/336/EEC)

(The CE Mark is only required in EC member states)

In compliance with VDE 0544 (EN 60974-1), the machines can be used in environments with

an increased electrical hazard.

2000 We reserve the right to make amendments. Art. No.: 099-000016-EWM01 Revised: 28.08.2000

Originaldokument

liegt jedem Gerät bei!

Original document

is enclosed with each machine!

Document original

est joint à toute machine!

EG - Konformitätserklärung

EU - conformity declaration

Déclaration de Conformidité de U.E.

Name des Herstellers:

Name of manufacturer:

Nom du fabricant:

EWM HIGHTEC WELDING GmbH

(nachfolgend EWM genannt)

(In the following called EWM)

(nommé par la suite EWM)

Anschrift des Herstellers:

Address of manufacturer:

Adresse du fabricant:

Dr.- Günter - Henle - Straße 8

D - 56271 Mündersbach –Germany

[email protected]

Hiermit erklären wir, daß das nachstehend

bezeichnete Gerät in seiner Konzeption und

Bauart sowie in der von uns in Verkehr ge-

brachten Ausführung den grundlegenden

Sicherheitsanforderungen der unten genannten

EG- Richtlinien entspricht. Im Falle von

unbefugten Veränderungen, unsachgemäßen

Reparaturen und / oder unerlaubten Umbauten,

die nicht ausdrücklich von EWM autorisiert sind,

verliert diese Erklärung ihre Gültigkeit.

We herewith declare that the machine described

below meets the standard safety regulations of the

EU- guidelines mentionned below in its conception

and construction, as well as in the design put into

circulation by us. In case of unauthorized changes,

improper repairs and / or unauthorized

modifications, which have not been expressly

allowed by EWM, this declaration will lose its

validity.

Par la présente, nous déclarons que la conception

et la construction ainsi que le modéle, mis sur le

marché par nous, de l´appareil décrit ci - dessous

correspondent aux directives fondamentales de

sécurité de la U.E. mentionnées ci- dessous. En cas

de changements non autorisés, de réparations

inadiquates et / ou de modifications prohibeés, qui

n´ont pas été autorisés expressément par EWM,

cette déclaration devientcaduque.

Gerätebezeichnung:

Description of the machine:

Déscription de la machine:

Gerätetyp:

Type of machine:

Type de machine:

Artikelnummer EWM:

Article number:

Numéro d´article

Seriennummer:

Serial number:

Numéro de série:

Optionen:

Options:

keine

none

aucune

Zutreffende EG - Richtlinien:

Applicable EU - guidelines:

Directives de la U.E. applicables:

EG - Niederspannungsrichtlinie (73/23/EWG)

EU - low voltage guideline

Directive de la U.E. pour basses tensions

EG- EMV- Richtlinie (89/336/EWG)

EU- EMC guideline

U.E.- EMC directive

Angewandte harmonisierte Normen:

Used co-ordinated norms:

Normes harmonisées appliquées:

EN 60974 / IEC 60974 / VDE 0544

EN 50199 / VDE 0544 Teil 206

Hersteller - Unterschrift:

Signature of manufacturer:

Signature du fabricant:

Michael Szczesny , Geschäftsführer

managing director

gérant 05.2000

Table of Content Page

Inhalt/1

Safety instructions................................................................................................................................Safety/1

For your safety .................................................................................................................................Safety/1

Transportation and set up .......................................................................................................................Safety/3

Notes on the use of these operating instructions....................................................................................Safety/3

General ........................................................................................................................................AI/1

About this machine manufactured in inverter technology...............................................................................AI/1

The advantages of inverter technology:.........................................................................................................AI/1

1 Technical data..................................................................................................................................... 1/1

1.1 Area of application...................................................................................................................... 1/1

2 Operating elements ............................................................................................................................ 2/1

3 Function specification logic control................................................................................................. 3/1

3.1 Logic control ............................................................................................................................... 3/1

3.2 Function sequence of TIG non-latched operation without UP/DOWN-SLOPE........................... 3/5

3.3 Function sequence of TIG non-latched operation with UP/DOWN-SLOPE................................ 3/6

3.4 Function sequence of TIG latched operation with UP/DOWN-SLOPE....................................... 3/7

3.5 MMA welding.............................................................................................................................. 3/8

3.6 Remote controls........................................................................................................................ 3/10

3.7 Interface for mechanised welding (remote control connection socket)..................................... 3/12

4Quick start – the shortest way to welding........................................................................................ 4/1

Table of Content Page

Inhalt/2

5 Commissioning................................................................................................................................... 5/1

5.1 Setting up the welding machine.................................................................................................. 5/1

5.2 Mains connection........................................................................................................................ 5/1

5.2.1 Switching the control transformer to 415V mains voltage ................................................ 5/1

5.3 Welding machine cooling system................................................................................................ 5/2

5.4 Workpiece lead........................................................................................................................... 5/2

5.5 Electrode holder (MMA welding).................................................................................................5/2

5.6 General information on connection of the TIG welding torch...................................................... 5/2

5.6.1 TIG welding torch connection........................................................................................... 5/3

5.6.2 TIG potentiometer welding torch connection.................................................................... 5/3

5.7 Shielding gas supply................................................................................................................... 5/3

5.7.1 Establishing the gas connections..................................................................................... 5/3

5.7.2 Currentless testing and setting the amount of shielding gas............................................ 5/4

6 Adjustment instructions (pending)................................................................................................... 5/4

7 Maintenance and care ........................................................................................................................ 7/1

8 Operating problems, causes and remedies ..................................................................................... 8/1

8.1 Customer checklist

inverte

r TIG 150 DC

......................................................................................... 8/1

8.2 Customer checklist

inverter

TIG 200 DC

powerSinus

.............................................................................. 8/2

8.3 Customer checklist

inverter

TIG 250 and 300 DC

............................................................................ 8/3

9. Spare parts list.................................................................................................................................... 9/1

10. Accessories....................................................................................................................................... 10/1

11. HF pulse generator HF-DC1/42 and ZGP1/8.0-4............................................................................. 11/1

12 Instruction Manual for Power Cooler Air Blast

Cooler Unit for a

inverter

TIG 200 DC

powerSinus

........................................................................................... 12/1

12.1 Description of Unit.......................................................................................................... 12/1

12.2 Technical Data................................................................................................................ 12/1

12.3 Operating Elements Front and Rear Views of Power Cooler Module ............................ 12/1

12.4 Commissioning............................................................................................................... 12/2

12.5 Spare Parts List.............................................................................................................. 12/3

13. Circuit diagrams................................................................................................................................ 13/1

Safety instructions

Safety /1

For Your Safety:

Warning: Observe accident prevention regulations.

Ignoring the following safety procedures can be fatal.

•Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves.

•Protect eyes and face with protective visor.

Electric shocks can be fatal

•The machine may only be connected to correctly earthed sockets.

•Only operate with intact connection lead including protective conductor and safety plug.

•An improperly repaired plug or damaged mains cable insulation can cause electric shocks.

•The machine may only be opened by qualified and authorised personnel.

•Before opening, pull out the mains plug. Switching off is not sufficient. Wait for 2 minutes

until capacitors are discharged.

•Always put down welding torch, stick electrode holder in an insulated condition.

Even touching low voltages can cause you to jump and lead to accidents, so:

•Safeguard yourself against falls, e.g. from a platform or scaffolding.

•When welding, operate earth tongs, torch and workpiece properly, not in ways for which they

are not intended. Do not touch live parts with bare skin.

•Only replace electrodes when wearing dry gloves.

•Never use torches or earth cables with damaged insulation.

Smoke and gases can lead to breathing difficulties and poisoning.

•Do not breathe in smoke and gases.

•Ensure that there is sufficient fresh air.

•Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarbon fumes can

be converted into poisonous phosgene by ultraviolet radiation.

Workpiece, flying sparks and droplets are hot

•Keep children and animals well away from the working area. Their behaviour is unpredictable.

•Move containers with inflammable or exposive liquids away from the working area.

There is a danger of fire and explosion.

•Never heat explosive liquids, dusts or gases by welding or cutting. There is also a danger of

explosion if apparently harmless substances in closed containers are able to build up excess

pressure when they are heated.

Take care to avoid fire hazards

•Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying, when

parts are glowing or hot slag is present.

•A constant check must be kept on whether fire hazards have been created in the working area.

•Highly inflammable objects, such as matches and cigarette lighters for example, must not be

carried in trouser pockets.

•You must ensure that fire extinguishing equipment - appropriate to the welding process - is

available close to the welding work area and that easy access is possible.

Safety instructions

Safety /2

Take care to avoid fire hazards

•Containers in which fuels or lubricants have been present must be thoroughly cleaned before

welding begins. It is not sufficient simply for the receptacle to be empty.

•After a workpiece has been welded, it must only be touched or brought into contact with

inflammable material when it has cooled down sufficiently.

•Loose welding connections can completely destroy protective conductor systems of interior

installations and cause fires. Before beginning welding work, ensure that the earth tongs are

properly fixed to the workpiece or welding bench and that there is a direct electrical connection

from the workpiece to the power source.

Noise exceeding 70 dBA can cause permanent hearing damage

•Wear suitable earmuffs or plugs.

•Ensure that other people who spend time in the working area are not inconvenienced by the

noise.

Secure gas cylinder

•Place shielding gas cylinders in the holders provided for them and secure with safety chains.

•Take care when handling cylinders; do not throw or heat, guard against them toppling over.

•When moving by crane, take off the gas cylinder from the welding machine.

Caution: Interference by electrical and electromagnetic fields is possible e.g. from the

welding machine or from the high-voltage pulses of the ignition unit.

•As laid down in Electromagnetic Compatibility Standard EN 50199, the machines are intended

for use in industrial areas; if they are operated e.g. in residential environments problems can

occur in ensuring electromagnetic compatibility.

•The functioning of heart pacemakers can be adversely affected when you are standing near

the welding machine.

•Malfunctioning of electronic equipment (e.g. EDP, CNC equipment) in the vicinity of the

welding location is possible.

•Other mains supply leads, trip leads, signal and telecommunications leads above, under and

near the welding device may be subject to interference.

Warning: Electromagnetic interference must be reduced to such a level that it no longer

constitutes interference.

Possible reduction measures:

•Welding machines should be regularly maintained (see Sect. “Maintenance and care”)

•Welding leads should be as short as possible and run closely together on or near to the

ground.

•Selective shielding of other leads and equipment in the environment can reduce radiation.

Caution: Repairs and modifications may only be carried out by authorised, trained,

specialist personnel.

The warranty becomes null and void in the event of unauthorised interference.

Our operating instructions will provide you with an introduction into the safe use of the

machine.

Therefore please read them closely and only start work when you are familiar with them.

Safety instructions

Safety /3

Transport and set-up

•Machines may only be moved and operated in an upright position.

•Before moving, pull out mains plug and place on the machine.

•Secure high-pressure shielding gas cylinder with safety chain to prevent it from toppling

over.

Environmental conditions:

The welding machine can be operated in a location where there is no risk of explosion at

•an ambient temperature of -10°C (plasma machines 0°C) to +40°C and

•a relative air humidity up to 50% at 40°C.

•where the surrounding air is free of unusual amounts of dust, acids, corrosive gases or

substances etc., insofar as they do not occur during welding.

Examples of unusual operating conditions:

Unusual corrosive smoke, vapour, excessive oil vapour, unusual vibrations or jolts, excessive

quantities of dust such as grinding dust etc., severe weather conditions, unusual conditions near

the coast or on board ship.

•When setting up the machine, ensure that air inlets and outlets are unobstructed.

The machine is tested to Protection Standard IP23, i.e.:

•Protection against penetration of solid foreign bodies ∅> 12mm,

•Protection against water spray up to an angle of 60° to the vertical.

Notes on the use of these operating instructions

These operating instructions are arranged in Sections.

To help you find your way around more quickly, in the margins you will occasionally see, in addition

to sub-headings, icons referring to particularly important passages of text which are graded as

follows depending on their importance:

(Note): Applies to special technical characteristics which the user must note.

(Warning): Applies to working and operating procedures which must be followed

precisely to avoid damaging or destroying the machine.

(Caution): Applies to working and operating procedures which must be followed

precisely to avoid endangering people and includes the “Warning” symbol.

Instructions and lists detailing step-by-step actions in given situations can be recognised

by bullet points, e.g.:

•Insert plug of welding current lead into socket (Sect. 5, G2) and lock.

Meaning of the diagram descriptions:

e.g. (C1) means: Item C / Figure 1 in the respective Section

e.g. (Sect. 3, C1) means: in Section 3 Item C / Figure 1

General

AL/1

About this machine manufactured in inverter technology

Congratulations.

You have purchased a modern and efficient welding machine in inverter technology.

In contrast to conventional power sources, it does not operate with 50Hz but with a 25kHz primary

driven transistor current source.

The advantages of inverter technology:

•Less effort in changing to another workplace because the machine dimensions and weight are

substantially reduced.

•Lower power consumption and smaller mains ratings by high efficiency (no losses).

•No need for expensive compensating equipment by a high cos phi and a correspondingly

smaller reactive current draw from the mains.

•Functional safety by robust construction, highly integrated electronic circuitry.

•High operating safety by thermal monitors in the power circuit.

•High control dynamics for the welding process. Therefore excellent welding and ignition results

and absolute reproducibility of all welding parameters.

•Welding result independent of mains voltage fluctuations.

•Easily serviced design by the use of modern, modular technology.

The

powerSinus

– Series:

The machines with

powerSinus series

have a built-in electronic switching unit which restricts the

current spikes coming from the mains supply and produces a pure Sinus-form of mains current. As

a result 200Amps welding current can be achieved from a 230V plug fused at 16Amps with

a cos phi of 1.

1 Technical data

1/1

inverter

with

S-sign

TIG 150 DC TIG 200 DC

powerSinus

TIG 250 DC TIG 300 DC

Adjustable:

Welding current 5A - 150A 5A - 200A 5A - 250A 5A - 300A

Welding voltage 10,1V - 26V 10V - 28V 10V - 30V 10V - 32V

Mains voltage

(tolerances) 1x230V (15%;-40%)

1x240V (10%;-40%) 1x230V (15%;-40%)

1x240V (10%;-40%) 3x400V (20%;-25%)

3x415V (15%;-25%) 3x400V (20%;-25%)

3x415V (15%;-25%)

Mains frequency 50/60Hz

Mains fuse

slow-blow 1 x 16A 1 x 16A 3 x 16A 3 x 16A

Welding current

TIG / MMA

25%duty cycle - / 150A - / 200A - / - - / -

35%duty cycle 150A / - 200A / - - / - - / -

40%duty cycle - / - - / - - / - 300A / 300A

60%duty cycle 116A / 97A 150A / 130A 250A / 250A 250A / 250A

100%duty cycle 90A / 75A 120A / 100A 190A / 190A 190A / 190A

Load alternation 10min (60% duty cycle ∧

6 min welding, 4min break)

Workpiece 35mm250mm2

Open circuit voltage 100V 75V 106V 106V

Efficiency 85% 89%

cos phi 0,99 1,0 0,99 0,99

Ambient temperature -10°C bis +40°C

Protection

classification IP 23

Insulation class H

Machine cooling fan

Torch cooling gas

Total weight 23kg 22kg 26kg 26kg

Dimensions (LxBxH) 450x290x400mm 530x260x400mm 480x355x400mm 480x355x400mm

Constructed to

standards VDE 0544 und EN 60974-1

SAll welding machines which carry the Smarking are constructed in accordance

with VDE 0544 (EN 60974-1) and can be used in working with increased hazard

of electrical shock

1.1 Area of application:

This machines are suitable exclusively for:

•TIG DC welding with HF and Liftarc ignition of all metals except aluminium.

•MMA DC welding.

All welding machines which carry the Smarking are constructed in accordance with VDE 0544

(EN 60974-1) and can be used in working with increased hazard of electrical shock

2 Operating elements

2/1

Fig. 1

inverter

TIG 150 DC

Fig. 2

inverter

TIG 200 DC

powerSinus

Fig. 3

inverter

TIG 250 DC

and

inverter

TIG300 DC

Item Symbol Description

A Mains ON/OFF Switch (

inverter

TIG 200 DC

powerSinus

at rear side)

B +Welding cable connector positive + for work piece cable TIG and MMA welding

C -Welding cable connector - ( for TIG- and MMA welding)

D Gas connection G 1/4" with power connection Minus -with HF

E Torch trigger connection socket (5 pole)

F Control panel (see Chap. Logic control)

G Remote control connection socket (14 pole)

H Hand crib

I Rubber feet

Air inlet openings

K Air outlet openings (Rear side)

ArcForce

RUTIL

2CELL

BASISCH

Rotary dial arcforcing device (only TIG 200/250/300)

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