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Summary of Contents for EWM microplasma 20
- Page 1 Operating instructions Welding machine microplasma 20 microplasma 50 microplasma 120 099-007010-EW501 07.09.2016...
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Page 2: General Instructions
+49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. -
Page 3: Table Of Contents
2.1.5 Calibration/Validation ....................12 3 Machine description – quick overview ....................13 Front view ............................ 13 3.1.1 microplasma 20, 50 ...................... 13 3.1.2 microplasma 120 ......................15 Rear view ............................. 17 Machine control – Operating elements ..................18 4 Design and function ..........................19 Transport and installation ...................... - Page 4 Meeting the requirements of RoHS ....................36 6 Rectifying faults............................ 37 Checklist for rectifying faults ......................37 7 Technical data............................38 microplasma 20-120 ........................38 8 Accessories ............................39 Welding torch cooling system ...................... 39 General accessories ........................39 Remote controls and accessories ....................39 9 Appendix A ............................
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Page 5: Safety Instructions
Contents Safety instructions Safety instructions Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... -
Page 6: Explanation Of Icons
Contents Notes on the use of these operating instructions 1.2.1 Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release/tap/tip user must observe. Switch off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Numerical value –... -
Page 7: Safety Instructions
Contents Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •... - Page 8 Contents Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times. The protective equipment has to include: •...
- Page 9 Contents Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
- Page 10 Contents Safety instructions CAUTION Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •...
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Page 11: Transport And Installation
Contents Transport and installation Transport and installation WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! • Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air! •... -
Page 12: Intended Use
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product. -
Page 13: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view 3.1.1 microplasma 20, 50 Figure 3-1 Item Symbol Description Carrying handle Cooling air outlet Main switch, machine on/off Plasma gas connecting nipple (G1/4” right) Connection to the welding torch or gas metering unit... - Page 14 Machine description – quick overview Front view Item Symbol Description Connection socket, 14-pole Remote control connection Connection socket, “+” welding current Connection for workpiece lead Pilot arc button with signal light Signal light off: pilot arc off Signal light on: pilot arc lit Toggle switch for no-power test Simulation option for the set parameter values without welding Cooling air inlet...
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Page 15: Microplasma 20, 50
Machine description – quick overview Front view 3.1.2 microplasma 120 Figure 3-2 Item Symbol Description Carrying handle Cooling air outlet Main switch, machine on/off Plasma gas connection (plug nipple type 20) Connection to the welding torch or gas metering unit Welding current connection socket, welding torch Machine feet 5-pole connection socket, welding torch control lead... - Page 16 Machine description – quick overview Front view Item Symbol Description Pilot arc button with signal light Signal light off: pilot arc off Signal light on: pilot arc lit Toggle switch for no-power test Simulation option for the set parameter values without welding Cooling air inlet Three-figure display Display of the welding voltage...
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Page 17: Rear View
Machine description – quick overview Rear view Rear view Figure 3-3 Item Symbol Description Ignition type changeover switch = HF ignition = Liftarc (contact ignition) G1/4" connecting nipple, shielding gas connection Connection to the pressure reducer G1/4" connecting nipple, plasma gas connection Connection to the pressure reducer Quick connect coupling (red) coolant return... -
Page 18: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 3-4 Item Symbol Description Operating mode rotary switch ------ not available -- Operating mode non-latched ------ Operating mode non-latched with Up- and Downslope ---- Operating mode latched with Up- und Downslope Excess temperature signal light / Welding torch cooling failure For error messages >... -
Page 19: Design And Function
Design and function Transport and installation Design and function Transport and installation WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. •... -
Page 20: Machine Cooling
Design and function Transport and installation 4.1.2 Machine cooling Insufficient ventilation results in a reduction in performance and equipment damage. • Observe the ambient conditions! • Keep the cooling air inlet and outlet clear! • Observe the minimum distance of 0.5 m from obstacles! 4.1.3 Workpiece lead, general CAUTION... -
Page 21: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 4.1.5 Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults in the arc (flickering). Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel. -
Page 22: Stray Welding Currents
Design and function Transport and installation Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! Always keep leads as short as possible! Lay any excess cable lengths in meanders. Figure 4-4 4.1.5.1 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and... -
Page 23: Mains Connection
Design and function Transport and installation 4.1.6 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only operate machine using a socket that has correctly fitted protective earth. • The mains voltage indicated on the rating plate must match the supply voltage. -
Page 24: Shielding And Plasma Gas Supply
Design and function Transport and installation 4.1.7 Shielding and plasma gas supply WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! • Place shielding gas cylinder into the designated holder and secure with fastening elements (chain/belt)! •... -
Page 25: Shielding Gas Hose Connection
Design and function Transport and installation 4.1.7.2 Shielding gas hose connection Figure 4-8 Item Symbol Description G1/4" connecting nipple, shielding gas connection Connection to the pressure reducer G1/4" connecting nipple, plasma gas connection Connection to the pressure reducer • Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow out any dirt. -
Page 26: Gas Test
Design and function Transport and installation 4.1.7.3 Gas test The connected gas lines should each have a pre-pressure of 4.5 bar (tolerance limits: plasma gas 4 bar to 5 bar, shielding gas 4 bar to 5 bar). The functional sequence for the gas test is carried out in the same way for shielding gas and plasma gas. -
Page 27: Welding Torch And Workpiece Line Connection
Design and function Transport and installation 4.1.8 Welding torch and workpiece line connection 4.1.8.1 microplasma 20, 50 Before commissioning, the plasma welding torch must be equipped for the welding JOB and correspondingly set/adjusted! Figure 4-10 Item Symbol Description Shielding gas connecting nipple (G1/4” left) Connection to the welding torch or gas metering unit Plasma gas connecting nipple (G1/4”... -
Page 28: Microplasma 120
Design and function Transport and installation 4.1.8.2 microplasma 120 Before commissioning, the plasma welding torch must be equipped for the welding JOB and correspondingly set/adjusted! Figure 4-11 Item Symbol Description Shielding gas connection (coupling type 20) Connection to the welding torch or gas metering unit Plasma gas connection (plug nipple type 20) Connection to the welding torch or gas metering unit Welding current connection socket, welding torch... -
Page 29: Function Sequences/Operating Modes
Design and function Transport and installation 4.1.9 Function sequences/operating modes 4.1.9.1 Currentless Test - Simulation mode Prior to beginning welding, the user can simulate the selected current and time parameters without actually welding. The toggle switch for no-power test is used for this. The selected current and time parameters can now be simulated as for the normal welding process. - Page 30 Design and function Transport and installation Non-latched mode Figure 4-13 1st cycle: • Press and hold torch trigger 1. • The gas pre-flow time elapses. • The arc ignites. • The welding current flows and immediately assumes the value of the starting current Is. •...
- Page 31 Design and function Transport and installation Latched mode Figure 4-14 1st cycle • Press torch trigger 1, the gas pre-flow time elapses. • The arc ignites. • Welding current flows and immediately assumes the set ignition current value (search arc at minimum setting). HF is switched off. 2nd cycle •...
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Page 32: 4.1.10 Welding Task Selection
Design and function Transport and installation 4.1.10 Welding task selection The basic prerequisite for starting the plasma process is a connected and functioning cooling circuit for cooling of the welding torch. Operating Action Result element Select operating mode Setting of welding parameters depending on welding task (currents and times). -
Page 33: Remote Control
Design and function Remote control Remote control The remote controls are operated on the 14-pole remote control connection socket. 4.2.1 FR21 14POL Functions • Foot-operated remote control, current • Infinitely adjustable welding current (0% to 100%) depending on the main current preselected at the welding machine •... -
Page 34: Interfaces For Automation
Design and function Interfaces for automation Interfaces for automation 4.3.1 Remote control connection socket, 14-pole Unsuitable control cables or incorrect input/output signal assignment can cause damage to the machine. Use shielded control cables only. Figure 4-15 Item Description X3/1 X3/2 NC (not assigned) X3/3 X3/4... -
Page 35: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER Incorrect maintenance and testing! The machine may be cleaned, repaired and tested by skilled and qualified personnel only. A qualified person is one who, due to their training, knowledge and experience, can detect any hazards and possible consequential damage when checking the machine, and can take the necessary safety measures. -
Page 36: Monthly Maintenance Tasks
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives on the Declaration of Conformity on your machine). -
Page 37: Rectifying Faults
Rectifying faults Checklist for rectifying faults Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dealer. -
Page 38: Technical Data
Technical data microplasma 20-120 Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! microplasma 20-120 microplasma 20 microplasma 50 microplasma 120 Machine type Setting range for welding current 0.1 A to 20 A 0.1 A to 50 A 0.5 A to 120 A... -
Page 39: Accessories
Accessories Welding torch cooling system Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Welding torch cooling system Type Designation Item no. UK 500 Air cooling unit 090-008026-00504 Reverse cooling unit 094-002283-00000 UKV4SET 4M Hose connection set... -
Page 40: Overview Of Ewm Branches
Appendix A Overview of EWM branches Appendix A Overview of EWM branches 099-007010-EW501 07.09.2016...
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