EWM TRITON 260 DC Operating Instructions Manual
  1. Manuals
  2. Brands
  3. EWM Manuals
  4. Welding System
  5. TRITON 260 DC
  6. Operating instructions manual
EWM TRITON 260 DC Operating Instructions Manual

EWM TRITON 260 DC Operating Instructions Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Operating instructions

Multi-process welding machines for
TIG welding
MMA welding
MIG/MAG welding (option)
•
TRITON 260 DC
•
TRITON 400 DC
•
TRITON 500 DC
These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machine 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 Directive (73/23/EEC)
• EC EMC Directive (89/336/EEC)
In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
© 2004
We reserve the right to make amendments.
EWM HIGHTEC WELDING GmbH
Dr. Günter - Henle - Straße 8; D-56271 Mündersbach
Phone: +49 (0)2680.181-0; Fax: +49 (0)2680.181-244
www.ewm.de
Internet:
; E-mail:
Art. No.: 099-000072-EWM01
info@ewm.de
GB
Revised: 19.08.04

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the TRITON 260 DC and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for EWM TRITON 260 DC

Summary of Contents for EWM TRITON 260 DC

  • Page 1: Operating Instructions

    EWM HIGHTEC WELDING GmbH Dr. Günter - Henle - Straße 8; D-56271 Mündersbach Phone: +49 (0)2680.181-0; Fax: +49 (0)2680.181-244 www.ewm.de info@ewm.de Internet: ; E-mail: Operating instructions Multi-process welding machines for TIG welding MMA welding MIG/MAG welding (option) • TRITON 260 DC •...
  • Page 2 / or unauthorized modifications, which changements autorisés, Veränderungen, unsachgemäßen have not been expressly allowed by EWM, réparations inadéquates Reparaturen und / oder unerlaubten this declaration will lose its validity. modifications prohibeés, qui n´ont pas été Umbauten, die nicht ausdrücklich von autorisés expressément par EWM, cette...

  • Page 3: Table Of Contents

    Table of contents Page Safety instructions ..........................S/1 For Your Safety .......................... S/1 Transport and set-up........................S/4 Notes on the use of these operating instructions............... S/4 Technical data ...........................1/1 TRITON 260........................1/1 TRITON 400/500 ......................1/2 Description of the machine ......................2/1 TRITON 260........................2/1 2.1.1 Front view......................2/1 2.1.2...
  • Page 4 Table of contents Page Quick start – the shortest way to welding ................4/1 Commissioning .........................5/1 Area of application ......................5/1 5.1.1 TRITON 260......................5/1 5.1.2 TRITON 400/500 ....................5/1 Setting up the welding machine..................5/1 Mains connection ......................5/1 5.3.1 Reconnecting the mains voltage 400/415V and 440/460V........5/1 Welding machine cooling system ..................5/2 Workpiece lead, general ....................5/2 Connection groups......................5/2...

  • Page 5: Safety Instructions

    Safety instructions For Your Safety Ignoring the following safety precautions can be fatal. Observe accident prevention regulations. Designed use This machine is manufactured according to the current state of the art and current regulations and standards. It is to be operated only for the designed use (see Chap. Commissioning/Area of application).
  • Page 6 Safety instructions 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.
  • Page 7 Safety instructions 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.

  • Page 8: Transport And Set-Up

    Safety instructions 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.
  • Page 9 Technical data TRITON 260 TRITON 260 Setting range: Welding current / voltage TIG, 5A/ 10.2V – 260A/ 20.4V 5A/ 20.2V – 230A/ 29.2V MIG/MAG 5A/ 14.3 – 240A/ 26V Max. welding current at MIG/MAG 20ºC ambient temperature: 50%DC 260A 230A 240A 60%DC 240A...

  • Page 10: Technical Data

    Technical data TRITON 400/500 TRITON 400 TRITON 500 Setting range: Welding current / voltage TIG, 5A/ 10,2V - 400A/ 26,0V 5A/ 10.1V -500 A/ 30.0V 5A/ 20,2V - 400A/ 36,0V 5A/ 20.1V -500A/ 40.0V MIG/MAG 5A/ 14,3V - 400A/ 30,0V 5A/ 14.2V -500A/ 39.0V Duty cycle at 40°C ambient temperature: 40%dc...

  • Page 11: Triton 260

    Description of the machine TRITON 260 2.1.1 Front view Fig. 2/1, Front view Item Symbol Description Carrying handle Carrying strap (no illustr.) Operating elements (see control T101, chap. 3.1) 5-pole connection socket: Standard TIG torch control lead 8-pole connection socket: TIG Up/Down or potentiometer torch control lead Welding current socket (welding current potential "+"): MMA welding: Workpiece or electrode holder connection,...
  • Page 12 Description of the machine 2.1.2 Rear view Fig. 2/2, Rear view Item Symbol Description 8-pole connection socket cooling unit control lead Main switch Welding machine and where appropriate cooling module "On/Off" Mains connection cable 7-pole connection socket wire feed unit control lead Connecting nipple G¼...

  • Page 13: Triton 400/500

    Description of the machine TRITON 400/500 2.2.1 Front view Fig. 2/3, Front view Item Symbol Description carrying handle Main switch Welding machine and where appropriate cooling module "On/Off" Operating elements (see control T101, chap. 3.1) 5-pole connection socket: TIG standard torch control lead 8-pole connection socket: TIG Up/Down or potentiometer torch control lead Air inlet 19-pole connection socket: Remote control connection...

  • Page 14: Rear View

    Description of the machine 2.2.2 Rear view Fig. 4/2, Rear view Item Symbol Description 7-pole connection socket wire feed unit control lead 8-pole connection socket cooling unit control lead Connecting nipple G¼ shielding gas connection to the pressure reducer Welding current socket - ; WF connection Welding current socket + Mains connection cable 4-pole connection socket cooling unit voltage supply...

  • Page 15: Operating Elements, Control T101

    Function specification Operating elements, control T101 Puls VOLT Arcforce T101 AMP % Fig. 3/1: Control T101 Item Symbol Description Changeover switch MMA / TIG welding process = MMA welding = TIG welding The changeover switch (A2) must be switched to TIG / MMA welding TIG pulse /standard welding changeover switch Puls...

  • Page 16: Additional Operating Elements Triton 260 (Mig/Mag Option)

    Function specification Item Symbol Description Gas post-flow time rotary dial The gas post-flow time is infinitely adjustable from 1 to 20 sec. Red LED (collective interference) If the collective interference LED lights up, the power unit is automatically switched off. Because some interferences are only brief and spurious (e.g. mains voltage surges), the LED extinguishes again and the welding machine is ready for welding.

  • Page 17: Additional Operating Elements Triton 400/500 (Mig/Mag Option)

    Function specification 3.1.2 Additional operating elements TRITON 400/500 GMAW MIG/MAG G3/4Si1 CO 100% G3/4Si1 CrNi 0,8...1,0 1,2...1,6 Ar/Mix 1,2...1,6 0,8...1,0 1,0...1,6 1,0...1,6 FCAW Al/Cu Arcforce MIG/MAG GMAW Fig. 3/3: Operating elements front view Item Symbol Description GMAW MIG/MAG or MMA / TIG welding process changeover switch MIG/MAG GMAW MIG/MAG...

  • Page 18: Tig Welding, General

    Function specification TIG welding, general If welding is performed alternately by different methods, e.g. TIG, MIG/MAG or MMA and if one or two welding torches and an electrode holder are connected to the machine, the open-circuit/welding voltage is applied simultaneously to both! Therefore, always place the torch and the electrode holder on an insulated surface before starting work and during breaks.

  • Page 19: Tig Welding Torch, Operating Variants

    Function specification 3.2.4 TIG welding torch, operating variants The welding process can be controlled with various torch designs (TT=torch trigger): 3.2.4.1 Standard TIG torch, 5-pole connection plug The welding machine is prepared for these torch types as standard. Symbol Description Functions Operation with Standard TIG torch...

  • Page 20: Tig Function Sequences

    Function specification TIG function sequences In the TIG operating modes, the following welding parameters can be adjusted via rotary dials: • Main current AMP, • Secondary current AMP%, • Down-slope time, • Gas post-flow time. Other welding parameters are preadjusted to optimum settings for most applications, but can be changed internally (see Chapter 3.9).

  • Page 21: Tig Non-Latched Operation

    Function specification 3.3.2 TIG non-latched operation • Adjust the appropriate changeover switches to the following settings: When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation. The Up- and Down-slopes are switched off. start Down Fig.

  • Page 22: Tig Latched Operation

    Function specification 3.3.3 TIG latched operation • Adjust the appropriate changeover switches to the following settings: When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation. The Up- and Down-slopes are switched off. AMP% start Down Fig.

  • Page 23: Tig Pulses, Function Sequences

    Function specification TIG pulses, function sequences The machines have an integrated TIG pulse device as standard. Entering the pulse parameters: • Pulse current = main current AMP, • Break current = secondary current AMP%. The times for the pulse and break current are pre-set at 0.3 sec ex works and can be changed internally (see Chap.

  • Page 24: Tig Pulses - Latched Operation

    Function specification 3.4.2 TIG pulses - latched operation • Adjust the appropriate changeover switches to the following settings: AMP% start Down Fig. 3/7: TIG latched function sequence MMA welding If welding is performed alternately by different methods, e.g. TIG, MIG/MAG or MMA and if one or two welding torches and an electrode holder are connected to the machine, the open-circuit/welding voltage is applied simultaneously to both! Therefore, always place the torch and the electrode holder on an insulated surface before...

  • Page 25: Triton 400/500 Adjustable Arcforcing

    Function specification 3.5.2 TRITON 400/500 adjustable arcforcing Adjustment at 8 levels is possible before and during the welding operation. Settings are made on the inner scale: "Rutile" setting:: Low arcforcing ⇒ gentle arc, little increased current before short-circuit. Used with stick electrodes enveloped with rutile. "Bas"...
  • Page 26 Function specification 3.6.2 TRITON 400/500 In MIG/MAG welding, only the following operating and display elements on the welding machine are active: • The digital display (D1), • the welding voltage or current changeover switch display (C1), • the roatry dial characteristic line (B3), •...

  • Page 27: Remote Control

    Function specification Remote control Only the remote controls described in these operating instructions should be connected. Plug in and lock the remote control to the remote control connection socket only, and only when the welding machine is switched off (chap. 2.1.1, G1 for TRITON 260 and chap. 2.2.1, G3 for TRITON 400/500).

  • Page 28: Tig Interface For Mechanised Welding (Remote Control Connection Socket)

    Function specification TIG interface for mechanised welding (remote control connection socket) The welding current sources feature a very high standard of safety. This safety standard is also retained when peripheral equipment is connected for automatic welding if this peripheral equipment fulfils the same criteria, particularly with regard to their isolation from the mains supply.

  • Page 29: Welding Parameter Adjustments "Internally

    Function specification Welding parameter adjustments "internally" The welding parameters are preadjusted to optimum settings for most applications, changes are only necessary for special applications. The welding parameters can be changed on the T101 circuit board in the welding machine. Explanation of symbols Symbol Meaning Jumper open...

  • Page 30: P1: I-Start Ignition Current

    Function specification 3.9.2 P1 I-start: Ignition current The ignition current is infinitely adjustable from 0% to 100% of the main current AMP (G1) (works setting 30%) Function Setting Increase ignition current Reduce ignition current (search arc in 0% position) 3.9.3 P2 t-UP: Up-slope time Current increase from the ignition current I to the value of the main current AMP (G1) infinitely...

  • Page 31: Programming Of The Torch Operation Variants

    Function specification 3.10 Programming of the torch operation variants The user can select the following functions (TT=torch trigger): • Operating modes standard TIG welding torch with 5-pole connector plug Mode1: Operation with standard TIG torch, welding current on/off, no Up/Down function (MG rocker or separate TT) Mode2: Up-Down operation with standard TIG torch (MG rocker) Mode3:...

  • Page 32: 3.10.3 Mode 3, Up/Down Operation For Standard Torches With Two Triggers

    Function specification 3.10.3 Mode 3, Up/Down operation for standard torches with two triggers Design: 2 trigger Symbol Functions Operation with Welding current On/Off TT 1 secondary current TT 1 in tapping mode Up/Down function TT 2 Down = press and hold Up = tap and hold Programming Mode3: •...

  • Page 33: Jp13, Jp14 And Jp15: Configure Welding Torch Connection

    Function specification 3.12 JP13, JP14 and JP15: Configure welding torch connection When connecting a potentiometer torch, the following jumpers must be changed inside the welding machine (see fig. 3.9): Welding torch configuration Setting Prepared for TIG standard or Up-Down torch (works setting) JP13 JP14 JP15...

  • Page 34: Triton 400/500 Interface For Mechanised Mig/Mag Welding (Option)

    Function specification 3.13 TRITON 400/500 interface for mechanised MIG/MAG welding (option) The welding current sources feature a very high standard of safety. This safety standard is also retained when peripheral equipment is connected for automatic welding if this peripheral equipment fulfils the same criteria, particularly with regard to their isolation from the mains supply.
  • Page 35 Quick start – the fastest way to weld Preparations Settings Settings and troubleshooting • Plug in the mains plug. • Set the welding process • Select arcforcing (Remember fuse protection!) (only applies to MMA applications and TRITON 400, 500) Arcforce •...

  • Page 36: Commissioning

    Commissioning Area of application 5.1.1 Designed use These welding machines are suitable exclusively for TIG, MMA and MIG/MAG welding. Any other use is regarded as "not as designed", and no liability is assumed for any damage arising therefrom. We can only guarantee smooth and trouble-free operation of the machines when used in conjunction with the cooling units, welding torches and accessories from our delivery programme! 5.1.2 Triton 260...

  • Page 37: Welding Machine Cooling System

    Commissioning Welding machine cooling system To obtain an optimal duty cycle from the power components, the following precautions should be observed: • Ensure that the working area is adequately ventilated, • Do not obstruct the air inlets and outlets of the machine, •...

  • Page 38: Mma Welding

    Commissioning MMA welding When replacing spent or new stick electrodes, always switch off the machine at the main switch. Always use insulated tongs to remove used stick electrodes or to move welded workpieces. Always put the electrode holder down when insulated. 5.7.1 Electrode holder •...

  • Page 39: Standard Tig Torch

    Commissioning 5.8.1.1 Standard TIG torch • Insert the torch control lead plug (5-pole) into the connection socket (A1) and lock. The welding machines are supplied as standard with torch trigger pin assignment B1 and gas connection G1/4". Fig. 5/5: Connection socket connection B1 5.8.1.2 TIG Up/Down or TIG potentiometer welding torch Potentiometer torches available on the market e.g.

  • Page 40: Mig/Mag Welding (Option)

    Commissioning MIG/MAG welding (option) Simultaneous TIG and MIG/MAG welding is not possible 5.9.1 TRITON 260 Always put down welding torch when insulated. In MIG/MAG welding, only the following operating and display elements on the welding machine are active: • Digital display (chap.3, D1), •...

  • Page 41: Triton 400/500

    Commissioning If a TIG torch and MIG/MAG torch are to be MIG/MAG- torch connected at the same time (e.g. frequent WF unit changing between the processes) blue blue the more powerful cooling unit COOL 71U41 ZWIPA should be used. Under certain circumstances, limitations in cooling output may arise despite the more powerful cooling unit;...

  • Page 42: Maintenance And Care

    Maintenance and care Under normal operating conditions, these welding machines are largely maintenance-free and require a minimum of care. However, a number of points should be observed to guarantee fault- free operation of your welding machine. Among these are regular cleaning and checking, as described below, depending on the level of contamination in the environment and the usage time of the welding machine.

  • Page 43: Repair Work

    Maintenance and care 6.2.3 Measurement of insulation resistance Disconnect the machine from the mains. Pull out the mains plug! Open the machine and clean carefully (as described above). Switch on mains switch. • Insulation resistance mains current circuit-casing Switch on mains switch. a) Step switch controlled machines: The machine must be opened.
  • Page 44 Operating faults, causes and remedies Customer checklist (TIG welding) All machines are subjected to strict manufacturing and final inspection procedures. If, despite this, something fails to work at any time, please check machine using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the machine, please inform your authorised dealer.

  • Page 45: Spare Parts List

    Ersatzteilliste / spare part list TRITON 260 TRITON 260 Abb. 8/1 front view / Fig. 8/1 Vorderseite Bezeichnung Description Art. Nr. / art. no. A1 + Gehäusedeckel Casing panel 094-007490-00001 (Option) Kippschalter Toggle switch 044-001939-00000 PCB Verbindungsplatine PCB connection DVM1/2 040-000449-00000 DVM1/2 Drehknopf...
  • Page 46 Ersatzteilliste / spare part list TRITON 260 Abb. 8/2 Rückseite / Fig. 8/2 rear view Pos Bezeichnung Description Artikelnummer Hauptschalter Mains switch 074-000279-00001 Kabelverschraubung Screwed cable gland 094-003293-00000 Mutter 024-000205-00001 Netzkabel Mains cable 092-000661-00000 Anschlußbuchse 8polig Connection socket 8-pole 094-006904-00000 PCB Verbindungsplatine PCB connection 040-000588-00000...
  • Page 47 Ersatzteilliste / spare part list TRITON 260 Abb. 8/4 linke Seite / Fig. 8/4 left side Pos Bezeichnung Description Artikelnummer Zündgerät Ignition unit 040-000546-00001 PCB Sperrwandler SPW 6 PCB blocking converter SPW 6 040-000556-00000 Multidul IGBT Multidul IGBT 080-000306-00000 Sicherung 1,6A 2x Fuse 1,6A 2x 044-001744-00000 PCB Schweißelektronik DC 260 PCB welding electronics DC 260 040-000583-00000...
  • Page 48 Ersatzteilliste / spare part list TRITON 400/500 Abb. 8/6 TRITON 400/500 Vorderseite; Fig. 8/6 TRITON 400/500 front view...
  • Page 49 Ersatzteilliste / spare part list Description Bezeichnung Art. Nr. / art. no. Griffstange Hand Grip 094-007501-00001 Halterung für Griffstange Hand Grip Mount 094-007383-00003 Gehäusedeckel Casing Panel 094-006540-00005 Steuerschalter Control Switch 094-000525-00000 Schaltergriff Switch Knob 094-001814-00000 PCB Verbindung PCB Connection 040-000449-00000 Pfeilscheibe Arrow Indicator 074-000235-00002...
  • Page 50 Ersatzteilliste / spare part list Abb. 8/7 TRITON 400/500 Rückseite; Fig. 8/7 TRITON 400/500 rear view Description Bezeichnung Art. Nr. / art. no. PCB Verbindung PCB Connection 040-000588-00000 Flanschdose Flange Socket 094-006904-00000 Schweissbuchse Welding Socket 074-000517-00000 Schlauchtülle Tube Bridge 094-000523-00004 Schnellkupplung Rot Rapid-Action Coupling Red 094-000520-00000...
  • Page 51 Ersatzteilliste / spare part list Abb. 8/8 TRITON 400 linke Seite; Fig. 8/8 TRITON 400 left side Description Bezeichnung Art. Nr. / art. no. Lüfter 074-000015-00000 PCB Schweisselektronik PCB Welding Electronics 040-000616-00000 Eingangsbrücke Input Bridge 064-000844-00016 Thyristor-Modul Thyristor-Module 064-000083-00014 Primärschalter Minus (2X) Primary Switch Minus (2X) 080-000301-00000 PCB Sperrwandler...
  • Page 52 Ersatzteilliste / spare part list Abb. 8/9 TRITON 400 rechte Seite; Fig. 8/9 TRITON 400 right side Description Bezeichnung Art. Nr. / art. no. PCB Brenner Taster Filter PCB Torch Trigger Filter 040-000545-00000 HF-Coil HF-Coil 040-000586-00000 Sättigungswandler Saturation Transformer 072-000537-00000 Baugruppe Sättigungswandler Componentry Saturation Transf.
  • Page 53 Ersatzteilliste / spare part list Abb. 8/10 TRITON 500 linke Seite; Fig. 8/10 TRITON 500 left side Description Bezeichnung Art. Nr. / art. no. PCB Zwischenkreis PCB Intermediate Circuit 040-000561-00000 PCB Schutzbeschaltung PCB Protective Wiring 042-000705-00000 PCB Zwischenkreis PCB Intermediate Circuit 040-000560-00000 PCB Treiberelektronik 4-Fach PCB Driver Electr.
  • Page 54 Ersatzteilliste / spare part list Abb. 8/11 TRITON 500 rechte Seite; Fig. 8/11 TRITON 500 right side Bezeichnung Description Art. Nr. / art. no. PCB Potiplatine PCB Poti 042-000498-00000 PCB Brenner Taster Filter PCB Torch Trigger Filter 040-000545-00000 HF-Coil HF-Coil 040-000586-00000 PCB Brenner Taster Filter PCB Torch Trigger Filter...

  • Page 55: Accessories, Options

    Accessories, options TRITON 260 9.1.1 Standard TIG torch Designation / description Article No. WIG torch 26 GD, 4m, two triggers 094-000538-00000 WIG torch 20 WD, 4m, two triggers 094-000487-00000 9.1.2 TIG Up/Down torch Designation / description Article No. WIG torch SRT26 Up-Down GD, 4m 094-007549-00000 WIG torch SRT20 Up-Down WD, 4m 094-007535-00000...

  • Page 56: Remote Control / Connection Cable

    Accessories, options TRITON 400/500 9.2.1 Standard TIG torch Designation / description Article No. WIG torch 18"SC" WD, 4m, two triggers 094-001172-00000 9.2.2 TIG Up/Down torch Designation / description Article No. WIG torch 18"SC" UP-DOWN WD, 4m, two triggers 094-007686-00000 9.2.3 Electrode holder /workpiece lead 9.2.3.1 TRITON 400...

  • Page 57: Circuit Diagrams

    Circuit diagram 10.1 TRITON 260 (Circuit diagrams are also in the machine) 10/1...
  • Page 58 Circuit diagram 10/2...

  • Page 59: Triton 400/500

    Circuit diagram 10.2 TRITON 360/500 (Circuit diagrams are also in the machine) 10/3...
  • Page 60 Circuit diagram 10/4...
  • Page 61 Circuit diagram 10/5...

This manual is also suitable for:

Triton 400 dcTriton 500 dc

Table of Contents