Related Manuals for EWM Microplasma 25
Summary of Contents for EWM Microplasma 25
- Page 1 Operating instructions Welding machine Microplasma 25 Microplasma 55 Microplasma 105 099-007027-EW501 Observe additional system documents! 28.08.2018...
- Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted.
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Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 Part of the complete documentation ....................8 Safety instructions .......................... - Page 4 Contents Notes on the use of these operating instructions 5.2.2 Pilot arc ......................... 38 5.2.2.1 Adjust pilot arc currents ................. 39 5.2.3 Expert Menu (Plasma) ....................40 TIG welding ..........................41 5.3.1 Welding task selection ....................41 5.3.2 Arc ignition ........................42 5.3.2.1 HF ignition .....................
- Page 5 Resetting welding parameters to the factory settings ..............74 Display machine control software version ................... 74 Checklist for rectifying faults ......................75 8 Technical data ............................76 Microplasma 25 ..........................76 Microplasma 55 ..........................77 Microplasma 105 .......................... 78 9 Accessories ............................79 Welding torch cooling system ......................
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Page 6: For Your Safety
For your safety Notes on the use of these operating instructions For your safety 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. •... -
Page 7: Explanation Of Icons
For your safety Explanation of icons 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 hold Switch Incorrect / Invalid Turn Numerical value –... -
Page 8: Part Of The Complete Documentation
For your safety Part of the complete documentation Part of the complete documentation These operating instructions are part of the complete documentation and valid only in combination with all other parts of these instructions! Read and observe the operating instructions for all system components, especially the safety instructions! The illustration shows a general example of a welding system. -
Page 9: Safety Instructions
For your safety 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 10 For your safety Safety instructions WARNING Explosion risk! Apparently harmless substances in closed containers may generate excessive pressure when heated. • Move containers with inflammable or explosive liquids away from the working area! • Never heat explosive liquids, dusts or gases by welding or cutting! Fire hazard! Due to the high temperatures, sparks, glowing parts and hot slag that occur during welding, there is a risk of flames.
- Page 11 For your safety Safety instructions CAUTION According to IEC 60974-10, welding machines are divided into two classes of electromagnetic compatibility (the EMC class can be found in the Technical data) > see 8 chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
- Page 12 For your safety Safety instructions The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •...
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Page 13: Transport And Installation
For your safety 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 14: Intended Use
Intended use Applications Intended use WARNING Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and standards applicable for use in industry and trade. It may only be used for the welding procedures indicated at the rating plate. -
Page 15: Documents Which Also Apply
3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity The labelled product complies with the following EC directives in terms of its design and construction: •... -
Page 16: Machine Description - Quick Overview
Machine description – quick overview Front view / side view from left Machine description – quick overview Front view / side view from left Figure 4-1 099-007027-EW501 28.08.2018... - Page 17 Machine description – quick overview Front view / side view from left Item Symbol Description Ready for operation signal light Signal light on when the machine is switched on and ready for operation Main switch, machine on/off Workpiece lead connection socket Pilot current connection socket Plasma welding torch nozzle potential 19-pole connection socket (analogue)
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Page 18: Rear View / Side View From Right
Machine description – quick overview Rear view / side view from right Rear view / side view from right The device configuration shown may differ in case of an additional ex works options or retrofitting options > see 9 chapter. Figure 4-2 099-007027-EW501 28.08.2018... - Page 19 Machine description – quick overview Rear view / side view from right Item Symbol Description 19-pole mechanised welding interface (analogue) > see 5.12.1 chapter 7-pole connection socket (digital) For connecting digital accessory components Key button, Automatic cutout Wire feed motor supply voltage fuse (press to reset a triggered fuse) 7-pole connection socket For connecting Wire feed unit...
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Page 20: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements 4.3.1 Overview of control sections For description purposes, the machine control has been divided into two sections (A, B) to ensure maximum clarity. The setting ranges for the parameter values are summarised in the parameter overview section >... -
Page 21: Control Section A
Machine description – quick overview Machine control – Operating elements 4.3.1.1 Control section A Figure 4-4 Item Symbol Description Welding data display (3-digit) Displays the welding parameters and the corresponding values > see 4.4.6 chapter Gas test push-button > see 5.1.8.2 chapter Operating mode >... -
Page 22: Control Section B
Machine description – quick overview Machine control – Operating elements Item Symbol Description Coolant fault signal light Signals pressure loss or low coolant level in the coolant circuit. Signal light Status display Hold After each completed welding task, the last values used in the welding process for the welding current and welding voltage are shown on the displays, and the signal light will be on Excess temperature signal light... - Page 23 Machine description – quick overview Machine control – Operating elements Item Symbol Description Parameter selection push-button, right The welding sequence parameters are selected one after another in a clockwise direction. For control systems without this button settings are done exclusively via the control button.
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Page 24: Operating The Machine Control
Machine description – quick overview Operating the machine control Operating the machine control 4.4.1 Main screen The machine control switches to the main screen after it has been turned on or a setting has been completed. This means that the previously selected settings (indicated by signal lights where applicable) and the nominal value for the current (A) are displayed in the left-hand welding data display. -
Page 25: Welding Data Display
Machine description – quick overview Operating the machine control 4.4.6 Welding data display The following welding parameters can be displayed before (nominal values), during (actual values) or after welding (hold values): Parameter Before welding During welding After welding (nominal values) (actual values) (hold values) Welding current... -
Page 26: Design And Function
Design and function Transport and installation Design and function WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •... -
Page 27: Workpiece Lead, General
Design and function Transport and installation 5.1.3 Workpiece lead, general CAUTION Risk of burning due to incorrect welding current connection! If the welding current plugs (machine connections) are not locked or if the workpiece connection is contaminated (paint, corrosion), these connections and leads can heat up and cause burns when touched! •... -
Page 28: 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 5-3 5.1.5 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and... -
Page 29: Mains Connection
Design and function Transport and installation 5.1.6 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • The connection (mains plug or cable), the repair or voltage adjustment of the device must be carried out by a qualified electrician in accordance with the respective local laws or national regulations! •... -
Page 30: Pressure Regulator Connection
Design and function Transport and installation 5.1.8 Pressure regulator connection Figure 5-6 Item Symbol Description Pressure regulator Output side of the pressure regulator Shielding gas cylinder Cylinder valve • Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow out any dirt. -
Page 31: Gas Test
Design and function Transport and installation Item Symbol Description Plasma gas G1/4" connecting nipple, shielding gas connection Connection to the pressure reducer G1/4" connecting nipple, plasma gas connection Connection to the pressure reducer • Check correct condition and sealing of tubes. Blow through gas hoses. •... -
Page 32: Welding Torch Cooling System
Design and function Transport and installation 5.1.9 Welding torch cooling system 5.1.9.1 Cooling unit connection Figure 5-8 Item Symbol Description Welding torch cooling unit Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply 5-pole connection socket Cooling unit voltage supply 8-pole connection socket Cooling unit control lead •... -
Page 33: Connection Of External Recooling Unit
Design and function Transport and installation 5.1.9.2 Connection of external recooling unit Figure 5-9 Item Symbol Description Welding torch cooling unit Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply • Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings: Return line red to quick connect coupling, red (coolant return) and supply line blue to quick connect coupling, blue (coolant supply). -
Page 34: 5.1.10 Welding Torch And Workpiece Line Connection
Design and function Transport and installation 5.1.10 Welding torch and workpiece line connection 5.1.10.1 Plasma welding Before commissioning, the plasma welding torch must be equipped for the welding JOB and correspondingly set/adjusted! Figure 5-10 Item Symbol Description Welding torch Torch hose package Pilot current connection socket Plasma welding torch nozzle potential Workpiece lead... -
Page 35: 5.1.10.2 Tig Welding
Design and function Transport and installation • Insert the plug on the welding current lead into the "-" welding current connection socket and lock. • Insert the plug of the pilot power line into the "+" pilot current connection socket. •... -
Page 36: 5.1.10.3 Connection Assignment, Welding Torch Control Cable
Design and function Transport and installation • Insert the plug on the welding current lead into the "-" welding current connection socket and lock. • Insert the torch control lead plug into the “5-pole connection socket, welding torch control lead” and lock. - Page 37 Design and function Transport and installation Item Symbol Description Stirrup Intermediate hose package strain relief Snap hooks Intermediate hose package strain relief > see 5.1.11 chapter • Insert the end of the hose package through the strain relief of the hose package and lock by turning to the right.
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Page 38: Plasma Welding
Design and function Plasma welding Plasma welding 5.2.1 Welding task selection The basic prerequisite for starting the plasma process is a connected and functioning cooling circuit for cooling of the welding torch. 5.2.1.1 Setting welding procedure Figure 5-14 5.2.2 Pilot arc Ignite pilot arc Figure 5-15 Switching off the pilot arc... -
Page 39: Adjust Pilot Arc Currents
Design and function Plasma welding 5.2.2.1 Adjust pilot arc currents The pilot arc current can be adapted to the welding process at four operating points: 1. Pilot arc standby current (during the welding pause) 2. Pilot arc ignition current (before welding) 3. -
Page 40: Expert Menu (Plasma)
Design and function Plasma welding 5.2.3 Expert Menu (Plasma) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of parameters shown may be limited, e.g. if a function is deactivated. ENTER EXIT Figure 5-18 Display Setting/selection Expert menu Slope time (main current to secondary current) -
Page 41: Tig Welding
Design and function TIG welding TIG welding 5.3.1 Welding task selection The setting of the tungsten electrode diameter has a direct influence on the machine functionality, TIG ignition behaviour and minimum current limits. The ignition energy is controlled by the set electrode diameter. -
Page 42: Arc Ignition
Design and function TIG welding 5.3.2 Arc ignition 5.3.2.1 HF ignition Figure 5-20 The arc is started without contact from high-voltage ignition pulses. a) Position the welding torch in welding position over the workpiece (distance between the electrode tip and workpiece should be approx. 2-3mm). b) Press the torch trigger (high voltage ignition pulses ignite the arc). -
Page 43: Expert Menu (Tig)
Design and function TIG welding 5.3.4 Expert menu (TIG) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of parameters shown may be limited, e.g. if a function is deactivated. ENTER EXIT Figure 5-22 Display Setting/selection Expert menu Slope time (main current to secondary current) -
Page 44: Aligning The Cable Resistance
Design and function TIG welding 5.3.5 Aligning the cable resistance To ensure optimum welding properties, the electric cable resistance should be aligned again whenever an accessory component such as the welding torch or the intermediate hose package (AW) has been changed. -
Page 45: Operating Modes (Functional Sequences)
Design and function Operating modes (functional sequences) 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle from the welding torch. • Unfasten the tungsten electrode and extract. 2 Configuration • Activate the rotary knob while switching on the welding machine at the same time. •... -
Page 46: Non-Latched Mode
Design and function Operating modes (functional sequences) Symbol Meaning Gas post-flow Balance Frequency 5.4.2 Non-latched mode Selection Figure 5-24 Sequence Figure 5-25 1st cycle: • Press torch trigger 1 and hold down. • Gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece. The arc ignites. •... -
Page 47: Latched Mode
Design and function Operating modes (functional sequences) 5.4.3 Latched mode Selection Figure 5-26 Sequence Figure 5-27 099-007027-EW501 28.08.2018... -
Page 48: Spotarc
Design and function Operating modes (functional sequences) 1st cycle • Press torch trigger 1 , the gas pre-flow time elapses. • HF start pulses jump from the electrode to the workpiece. The arc ignites. • Welding current flows and immediately assumes the set ignition current (search arc at minimum setting). -
Page 49: Spotmatic (Plasma)
Design and function Operating modes (functional sequences) Figure 5-29 Sequence: • Press torch trigger and hold down. • The gas pre-flow time elapses. • Arc ignites (main arc ignition for plasma / HF ignition at TIG) • The welding current flows and immediately assumes the value of the ignition current •... -
Page 50: Spotmatic (Tig)
Design and function Operating modes (functional sequences) 5.4.6 spotmatic (TIG) In contrast to the spotArc operating mode, the arc is not ignited by pressing the torch trigger as is usual, but by briefly touching the tungsten electrode against the workpiece. The torch trigger is used for welding process activation. -
Page 51: Non-Latched Operation, Version C
Design and function Operating modes (functional sequences) As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however > see 5.3.2 chapter. Selecting the process activation type for the welding process > see 5.13 chapter. Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 s) only. -
Page 52: Recurring Welding Tasks
Design and function Recurring welding tasks Recurring welding tasks The user has additional memory locations at their disposal to save recurring or different welding tasks on a permanent basis (101 plasma JOBs / 8 WIG JOBs). To do so, simply select the required memory location and set the welding task as described previously. -
Page 53: Thermal Pulsing
Design and function Pulse welding 5.6.2 Thermal pulsing The operation sequences basically match the standard welding sequences, but there is an additional switching back and forth between the main current AMP (pulse current) and the secondary current AMP% (pulse pause current) at the set times. Pulse and pause times and the pulse edges ( ) are entered in seconds on the control. -
Page 54: Pulsed Welding In The Upslope And Downslope Phases
Design and function Pulse welding Pulse pause setting EXIT Figure 5-38 Pulse edge setting pulse edges can be set in the Expert menu (TIG) > see 5.3.4 chapter. 5.6.2.1 Pulsed welding in the upslope and downslope phases The pulse function can also be deactivated if necessary during the up-slope and down-slope phases (parameter ) >... - Page 55 Design and function Pulse welding Selection Figure 5-41 Balance setting EXIT Figure 5-42 Frequency setting EXIT Figure 5-43 099-007027-EW501 28.08.2018...
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Page 56: Average Value Pulse Welding
Design and function Welding torch (operating variants) 5.6.4 Average value pulse welding A special feature with average value pulses is that the power source will always maintain the preset average value. This makes this method especially suitable for welding according to welding procedure specifications. -
Page 57: Torch Mode Setting
Design and function Welding torch (operating variants) 5.7.2 Torch mode setting Modes 1 to 6 and 11 to 16 are available to the user. Modes 11 to 16 feature the same functionality as 1 to 6, but without the tapping function > see 5.7.1 chapter for the secondary current. The functionality of the individual modes can be found in the corresponding torch type tables. -
Page 58: Standard Tig Torch (5-Pole)
Design and function Standard TIG torch (5-pole) Standard TIG torch (5-pole) Standard torch with one torch trigger Figure Operating Explanation of symbols elements BRT1 = torch trigger 1 (welding current on/off; secondary current via tapping function) Functions Mode Operating elements Welding current on/off (ex works) Secondary current (latched operation) -
Page 59: Remote Control
Design and function Remote control Standard torch with one rocker (rocker, two torch triggers) Figure Operating Explanation of symbols elements BRT 1 = torch trigger 1 BRT 2 = torch trigger 2 Functions Mode Operating elements Welding current on/off Secondary current (ex works) Secondary current (tapping function) )/(latched operating mode) -
Page 60: Rtf Start Ramp
Design and function Remote control 5.9.1.1 RTF start ramp The RTF start ramp function prevents the energy input at the start of welding from being too high and too fast should the user press the remote control pedal too fast and too strongly. Example: The user sets the main current at the welding machine to 200 A. -
Page 61: Rtf Response
Design and function Remote control 5.9.1.2 RTF response This function controls the current response during the main current phase. The user can choose between linear and logarithmic response. The logarithmic setting is especially suited for welding with low currents, e.g. for thin panels, as the logarithmic response enables a better control of the welding current. In the machine configuration menu, the RTF response function can be toggled between linear response... -
Page 62: Power-Saving Mode (Standby)
Design and function Power-saving mode (Standby) Standard operation • Set welding current I1 (0-100% of rotary knob (AMP) on the welding machine) • Set the secondary current I2 (0-100% of the rotary knob), accessible via the 2 torch trigger. 5.10 Power-saving mode (Standby) You can activate the power-saving mode by either pressing the push-button >... -
Page 63: 5.12.1 Automation Interface
Design and function Interfaces for automation 5.12.1 Automation interface This accessory component is only available as a “factory-fit option”. WARNING No function of the external interrupt equipment (emergency stop switch)! If the emergency stop circuit has been set up using an external interrupt equipment connected to the interface for automated welding, the machine must be configured for this setup. -
Page 64: 5.12.2 Remote Control Connection Socket, 19-Pole
Design and function Machine configuration menu 5.12.2 Remote control connection socket, 19-pole Figure 5-47 Pos. Signal shape Designation Output Connection for cable screen (PE) Output Current flows signal I>0, galvanically isolated (max. +- 15V/100mA) Output Reference voltage for potentiometer 10V (max. 10mA) Input Control value specification for main current, 0-10V (0V = I , 10V =... -
Page 65: Machine Configuration Menu
Design and function Machine configuration menu 5.13 Machine configuration menu Basic machine settings are defined in the machine configuration menu. 5.13.1 Selecting, changing and saving parameters ENTER EXIT NAVIGATION Figure 5-48 Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode (ex works 1) >... - Page 66 Design and function Machine configuration menu Display Setting/selection Alternative welding start – tapping start Available from torch mode 11 (welding stop by tapping remains active). ------- Function enabled (ex works) ------- Function disabled Up/down speed > see 5.7.3 chapter Increase value > rapid current change Decrease value >...
- Page 67 Design and function Machine configuration menu Display Setting/selection RTF start ramp > see 5.9.1.1 chapter ------- Welding current rises to the specified main current level in a ramp function (ex works) ------- Welding current immediately jumps to the specified main current level RTF response >...
- Page 68 Design and function Machine configuration menu Display Setting/selection Minimum current limit (TIG) > see 5.3.1 chapter Depending on the set tungsten electrode diameter ------- Function disabled ------- Function enabled (ex works) Access control – access code Setting: 000 to 999 (000 ex works) Access control >...
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Page 69: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed. -
Page 70: Maintenance Work, Intervals
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-007027-EW501 28.08.2018... -
Page 71: Disposing Of Equipment
• Information about returning used equipment or about collections can be obtained from the respective municipal administration office. • In addition to this, returns are also possible throughout Europe via EWM sales partners. 099-007027-EW501 28.08.2018... -
Page 72: Rectifying Faults
Rectifying faults Warnings 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 73: Error Messages
Rectifying faults Error messages Error messages A welding machine error will be signalled by an error code (see table) on the control display. In the event of an error, the power unit shuts down. The display of possible error numbers depends on the machine version (interfaces/functions). •... -
Page 74: Resetting Welding Parameters To The Factory Settings
Rectifying faults Resetting welding parameters to the factory settings Error message Possible cause Remedy If the error persists, contact service. Err 39 Electronics error (secondary overvoltage) Err 40 Electronics error (I>0 error) Inform service Err 48 Ignition error Check welding process Err 49 Arc interruption Inform service... -
Page 75: Checklist For Rectifying Faults
Rectifying faults Checklist for rectifying faults Checklist for rectifying faults Legend Symbol Description Fault/Cause Remedy The correct machine equipment for the material and process gas in use is a fundamental requirement for perfect operation! No arc ignition Incorrect ignition type setting. Ignition type: Select “HF start”. -
Page 76: Technical Data
Technical data Microplasma 25 Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Microplasma 25 Plasma Welding current (I 0,3 A up to 20 A 2 A up to 20 A Welding voltage according to... -
Page 77: Microplasma 55
Technical data Microplasma 55 Microplasma 55 Plasma Welding current (I 0,3 A up to 50 A 2 A up to 50 A Welding voltage according to 25,0 V up to 27,0 V 10,1 V up to 12,0 V Standard (U Plasma current (pilot arc) 2-15 A Duty cycle at 40°... - Page 78 Technical data Microplasma 105 Microplasma 105 Plasma Welding current (I 0,3 A up to 100 A 2 A up to 100 A Welding voltage according to 25,0 V up to 29,0 V 10,1 V up to 14,0 V Standard (U Plasma current (pilot arc) 2-15 A Duty cycle at 40°...
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Page 79: 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. Cool 50 MPW50 Cooling module with centrifugal pump 090-008818-00502 KF 23E-10, -10 Coolant (-10 °C), 9,3 l... -
Page 80: Parameter Overview - Setting Ranges
Appendix A Parameter overview – setting ranges Appendix A Parameter overview – setting ranges 10.1 Name Display Setting range Main current AMP, depending on power source Gas pre-flow time Ignition current, percentage of AMP Ignition current, absolute, depending on power source Start time 0,01 0,01 -... -
Page 81: Searching For A Dealer
Appendix B Searching for a dealer Appendix B 11.1 Searching for a dealer Sales & service parteners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-007027-EW501 28.08.2018...
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