Related Manuals for EWM Microplasma 25-2 PG RC
Summary of Contents for EWM Microplasma 25-2 PG RC
- Page 1 Operating instructions Welding machine Microplasma 25-2 PG RC Microplasma 55-2 PG RC Microplasma 105-2 PG RC 099-007033-EW501 Observe additional system documents! 4.1.2022...
- 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 using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................5 Notes on using these operating instructions ................5 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ....................10 3 Intended use .......................... - Page 4 Display machine control software version ................60 Checklist for rectifying faults ....................60 8 Technical data ..........................62 Microplasma 25-2 PG RC ....................62 Microplasma 55-2 PG RC ....................63 Microplasma 105-2 PG RC ....................64 9 Accessories ..........................65 Welding torch cooling system ....................
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Page 5: For Your Safety
For your safety Notes on using these operating instructions For your safety Notes on using 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
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 Correct / Valid Numerical value –... -
Page 7: 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 8 For your safety 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.
- Page 9 For your safety 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! •...
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Page 10: Transport And Installation
For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the in- troduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines. - Page 11 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.
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Page 12: Intended Use
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 This product corresponds in its design and construction to the EU directives listed in the decla- ration. -
Page 13: Part Of The Complete Documentation
Intended use Documents which also apply 3.3.6 Part of the complete documentation This document is 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 compo- nents, especially the safety instructions! Figure 3-1 The illustration shows a general example of a welding system. -
Page 14: 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 4-1 099-007033-EW501 4.1.2022... - Page 15 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 Switching the machine on or off. Workpiece lead connection socket Pilot current connection socket Plasma welding torch nozzle potential...
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Page 16: 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 4-2 099-007033-EW501 4.1.2022... - Page 17 Machine description – quick overview Rear view / side view from right Item Symbol Description 19-pole mechanised welding interface (analogue) > see 5.7.1 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 18: 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 19: 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 5.1.7.3 chapter Operating mode / power-saving mode push-button ---------- Latched ------- Non-latched... -
Page 20: 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. Hold Signal light Status display 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 21 Machine description – quick overview Machine control – Operating elements Item Symbol Description Control button Central control button to be pressed or turned > see 4.4 chapter. Parameter selection push-button, right The welding sequence parameters are selected one after another in a clockwise direc- tion.
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Page 22: 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 com- pleted. 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 23: 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 af- ter welding (hold values): Parameter Before welding During welding After welding (nominal values) (actual values) (hold values) Welding current... -
Page 24: 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 25: 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 26 Design and function Transport and installation • Use an individual welding lead to the workpiece for each welding machine! Figure 5-2 • 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.
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Page 27: Stray Welding Currents
Design and function Transport and installation 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 electronic devices and cause overheating of components, leading to fire. •... -
Page 28: 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 na- tional regulations! •... -
Page 29: Pressure Regulator Connection
Design and function Transport and installation 5.1.7.1 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 30: 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 Connecting nipple G1/4“ plasma gas, inlet Connection to pressure regulator • Check correct condition and sealing of tubes. Blow through gas hoses. •... -
Page 31: Welding Torch Cooling System
Design and function Transport and installation 5.1.8 Welding torch cooling system 5.1.8.1 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 32: Connection Of External Recooling Unit
Design and function Transport and installation 5.1.8.2 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 33: Welding Torch And Workpiece Line Connection
Design and function Transport and installation 5.1.9 Welding torch and workpiece line connection 5.1.9.1 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 34: 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 35 Design and function Transport and installation • Insert the plug on the welding current lead into the "-" welding current connection socket and lock. • Insert the quick-release nipple of the protective gas line onto the quick connect coupling type 20. •...
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Page 36: 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 5-12 5.2.2 Pilot arc Ignite pilot arc Figure 5-13 Switching off the pilot arc... -
Page 37: 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 38: 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 pa- rameters shown may be limited, e.g. if a function is deactivated. ENTER EXIT Figure 5-16 Display Setting/selection Expert menu... -
Page 39: 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 diam- eter. -
Page 40: Arc Ignition
Design and function TIG welding 5.3.2 Arc ignition 5.3.2.1 HF ignition Figure 5-18 The arc is started without contact using high-voltage ignition pulses: a) Position the welding torch in the welding position above the workpiece (distance between the elec- trode tip and the workpiece approx. 2-3 mm). b) Press the torch trigger (high-voltage ignition pulses start the arc). -
Page 41: 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 pa- rameters shown may be limited, e.g. if a function is deactivated. ENTER EXIT Figure 5-20 Display Setting/selection Expert menu... -
Page 42: 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 43: Recurring Welding Tasks
Design and function Recurring welding tasks 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 44: Pulse Welding
Design and function Recurring welding tasks 5.4.1 Pulse welding The following pulse types can be selected: • Automated pulsing • Thermal pulsing • Metallurgical pulsing • Average value pulsing 5.4.1.1 Automated pulses The automated pulsing pulse variant is only activated for DC welding in combination with the spotArc op- erating mode. -
Page 45: Pulsed Welding In The Upslope And Downslope Phases
Design and function Recurring welding tasks Pulse time setting Figure 5-26 Pulse pause setting Figure 5-27 Pulse edge setting pulse edges can be set in the Expert menu (TIG) > see 5.3.4 chapter. 5.4.1.3 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 46: Metallurgical Pulsing (Khz Pulsing)
Design and function Recurring welding tasks 5.4.1.4 Metallurgical pulsing (kHz pulsing) Metallurgical pulsing (kHz pulsing) uses the plasma force (arc force) occurring at high currents which al- lows you to achieve a constricted arc with concentrated heat input. Unlike thermal pulsing, no times are set;... -
Page 47: Average Value Pulse Welding
Design and function Power-saving mode (Standby) Frequency setting Figure 5-32 5.4.2 Average value pulse welding A special feature with average value pulses is that the power source will always maintain the preset aver- age value. This makes this method especially suitable for welding according to welding procedure specifi- cations. -
Page 48: Access Control
Design and function Access control Access control The machine control can be locked to secure it against unauthorised or unintentional adjustment. The access block has the following effect: • The parameters and their settings in the machine configuration menu, Expert menu and operation se- quence can only be viewed but not changed. -
Page 49: Automation Interface
Design and function Interfaces for automation 5.7.1 Automation interface These accessory components can be retrofitted as an option > see 9 chapter. 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 50: Busint X11 Industrial Bus Interface
Design and function PC interface 5.7.3 BUSINT X11 industrial bus interface The solution for easy integration with automated production with e.g. • Profinet/Profibus • EnthernetIP/DeviceNet • EtherCAT etc. PC interface Welding parameter software Set all welding parameters on the PC and simply transfer to one or more welding machines (accessory, set consisting of software, interface, connection leads) •... -
Page 51: Machine Configuration Menu
Design and function Machine configuration menu Machine configuration menu Basic machine settings are defined in the machine configuration menu. 5.9.1 Selecting, changing and saving parameters ENTER EXIT NAVIGATION Figure 5-35 Display Setting/selection Exit the menu Exit Torch configuration menu Set welding torch functions Torch mode (ex works 1) 099-007033-EW501 4.1.2022... - Page 52 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 Increase value > rapid current change Decrease value >...
- Page 53 Design and function Machine configuration menu Display Setting/selection RTF start ramp -------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 -------Linear response -------Logarithmic responsive (ex works) spotmatic operating mode Ignition by contact with the workpiece...
- Page 54 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 55: 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 56: 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! 099-007033-EW501 4.1.2022... -
Page 57: Disposing Of Equipment
Information on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further information on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html. -
Page 58: 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 59: Error Messages
Rectifying faults Error messages Error messages Depending on the options of the machine display, a fault is shown as follows: Display type - machine control Display Graphic display two 7-segment displays one 7-segment display The possible cause of the fault is signalled by a corresponding fault number (see table). In the case of an error, the power unit shuts down. -
Page 60: Resetting Welding Parameters To The Factory Settings
Rectifying faults Resetting welding parameters to the factory settings Error Possible cause Remedy Electronics error (I>0 error) Electronics error (Uact error) Switch the machine off and on. If the error persists, no- Electronics error (A/D channel error) tify Service. Electronics error (slope error) Electronics error (S sign) Electronics error (temperature error) Allow the machine to cool. - Page 61 Rectifying faults Checklist for rectifying faults Pore formation Inadequate or missing gas shielding Check shielding gas setting and replace shielding gas cylinder if necessary Shield welding site with protective screens (draughts affect the welding result) Use gas lens for aluminium applications and high-alloy steels ...
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Page 62: Technical Data
Technical data Microplasma 25-2 PG RC Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Microplasma 25-2 PG RC Plasma Welding current (I 0,3 A to 20 A 2 A to 20 A Welding voltage according to standard (U... -
Page 63: Microplasma 55-2 Pg Rc
Technical data Microplasma 55-2 PG RC Microplasma 55-2 PG RC Plasma Welding current (I 0,3 A to 50 A 2 A to 50 A Welding voltage according to standard (U 25,0 V to 27,0 V 10,1 V to 12,0 V Plasma current (pilot arc) 2-6 A Duty cycle DC at 40°... -
Page 64: Microplasma 105-2 Pg Rc
Technical data Microplasma 105-2 PG RC Microplasma 105-2 PG RC Plasma Welding current (I 0,3 A to 100 A 2 A to 100 A Welding voltage according to standard (U 25,0 V to 29,0 V 10,1 V to 14,0 V Plasma current (pilot arc) 2-6 A Duty cycle DC at 40°... -
Page 65: Accessories
Designation Item no. RINT X12 STANDARD Robot interface 090-008291-00000 ON PLUG SET RINT X12 Optional EWM plug set, retrofit kit for RINT X12 092-001822-00000 RA5 19POL 1x 5M Connection cable, 19-pole, 5 m 092-001569-00005 FRV 7POL 10 m Extension/connecting cable... -
Page 66: Appendix
Appendix Parameter overview – setting ranges Appendix 10.1 Parameter overview – setting ranges Name Display Setting range Main current AMP, depending on power source Gas pre-flow time Start current, percentage of AMP Start current, absolute, depending on power source Start time 0,01 0,01 - 20,0... -
Page 67: Searching For A Dealer
Appendix Searching for a dealer 10.2 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-007033-EW501 4.1.2022...
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