EWM inverter TIG 150 DC Operating Instructions Manual
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EWM inverter TIG 150 DC Operating Instructions Manual

EWM inverter TIG 150 DC Operating Instructions Manual

Inverter tig dc welding machines from 150a – 300a portable
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Operating instructions

inverter
These operating instructions must be read before commissioning!
Failure to do so may be dangerous!
Machines may only be operated by personnel familiar with the appropriate safety regulations!
The machines bear the conformity mark - and thus comply with the
? EC Low Voltage Guideline (73/23/EEC)
? EC EMV Directive (89/336/EEC)
(The CE Mark is only required in EC member states)
In compliance with VDE 0544 (EN 60974-1), the machines can be used in environments with
an increased electrical hazard.
© 2000
We reserve the right to make amendments.
TIG DC welding machines
from 150A – 300A
portable
inverter
TIG 200 DC
power
Cooler
inverter
TIG 150 DC
inverter
TIG 250 DC
inverter
TIG 300 DC
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:
powerSinus
Art. No.: 099-000016-EWM01
info@ewm.de
Revised: 28.08.2000

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  • 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 inverter TIG DC welding machines from 150A – 300A portable inverter powerSinus TIG 200 DC...
  • Page 2 / ou de modifications prohibeés, qui Reparaturen und / oder unerlaubten Umbauten, allowed by EWM, this declaration will lose its n´ont pas été autorisés expressément par EWM, die nicht ausdrücklich von EWM autorisiert sind, validity.

  • Page 3: Table Of Contents

    Table of Content Page Safety instructions..........................Safety/1 For your safety ..........................Safety/1 Transportation and set up ........................Safety/3 Notes on the use of these operating instructions ..................Safety/3 General ............................AI/1 About this machine manufactured in inverter technology................AI/1 The advantages of inverter technology: ......................AI/1 Technical data .............................
  • Page 4 Table of Content Page Commissioning ........................... 5/1 Setting up the welding machine....................5/1 Mains connection........................5/1 5.2.1 Switching the control transformer to 415V mains voltage ..........5/1 Welding machine cooling system....................5/2 Workpiece lead ........................... 5/2 Electrode holder (MMA welding)....................5/2 General information on connection of the TIG welding torch............

  • Page 5: Safety Instructions

    Safety instructions For Your Safety: Warning: Observe accident prevention regulations. Ignoring the following safety procedures can be fatal. • Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves. • Protect eyes and face with protective visor. Electric shocks can be fatal •...
  • Page 6 Safety instructions Take care to avoid fire hazards • Containers in which fuels or lubricants have been present must be thoroughly cleaned before welding begins. It is not sufficient simply for the receptacle to be empty. • After a workpiece has been welded, it must only be touched or brought into contact with inflammable material when it has cooled down sufficiently.

  • Page 7: Notes On The Use Of These Operating Instructions

    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 8: General

    General About this machine manufactured in inverter technology Congratulations. You have purchased a modern and efficient welding machine in inverter technology. In contrast to conventional power sources, it does not operate with 50Hz but with a 25kHz primary driven transistor current source. The advantages of inverter technology: •...

  • Page 9: Technical Data

    Technical data inverter TIG 150 DC TIG 200 DC TIG 250 DC TIG 300 DC with -sign powerSinus 5A - 150A 5A - 200A 5A - 250A 5A - 300A Adjustable: Welding current Welding voltage 10,1V - 26V 10V - 28V 10V - 30V 10V - 32V 1x230V (15%;-40%)

  • Page 10: Operating Elements

    Operating elements inverter inverter powerSinus Fig. 1 TIG 150 DC Fig. 2 TIG 200 DC inverter inverter TIG 250 DC and TIG300 DC Fig. 3 Item Symbol Description inverter powerSinus Mains ON/OFF Switch ( TIG 200 DC at rear side) Welding cable connector positive + for work piece cable TIG and MMA welding Welding cable connector - ( for TIG- and MMA welding) Gas connection G 1/4"...

  • Page 11: Logic Control

    Function specification Logic control Fig. 1: Logic control INTIG03...
  • Page 12 Function specification Rotary switch The following operating modes can be preselected: • Non-latched operation without UP-SLOPE / DOWN-SLOPE • Non-latched operation with UP-SLOPE / DOWN-SLOPE • Latched operation with UP-SLOPE / DOWN-SLOPE • MMA operating mode UP-SLOPE UP-SLOPE (current increase) The increase in current from the ignition current I (E1) to the main current value (F1) can be infinitely adjusted between 0-25 sec with this rotary dial.
  • Page 13 Function specification DOWN-SLOPE DOWN-SLOPE (current fall) The fall in the main current I (F1) to the end-crater current (minimum current) can be infinitely adjusted between 0 - 25 sec with this rotary dial. Gas post-flow time 0sec. 20sec. Selects the gas post-flow time between 0-20 sec. Note: The gas pre-flow time can be infinitely adjusted internally from 0.2-5 s.
  • Page 14 Function specification 0000 Digital ammeter Displays the welding current at all times. Red LED collective interference If the collective interference LED lights, 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 15: Function Sequence Of Tig Non-Latched Operation Without Up/Down-Slope

    Function specification Function sequence of TIG non-latched operation without UP/DOWN-SLOPE Set the rotary switch to the position (non-latched without slope) Set the changeover switch to the position (HF ignition on) 1st step: • Operate the torch trigger. • The gas pre-flow time passes. •...

  • Page 16: Function Sequence Of Tig Non-Latched Operation With Up/Down-Slope

    Function specification Function sequence of TIG non-latched operation with UP/DOWN-SLOPE Rotary switch in the position (non-latched with slope) Changeover switch in the position (HF ignition on) 1st step: • Operate the torch trigger. • The gas pre-flow time passes. • HF ignition pulses jump from the electrode to the workpiece, the arc ignites. •...

  • Page 17: Function Sequence Of Tig Latched Operation With Up/Down-Slope

    Function specification Function sequence of TIG latched operation with UP/DOWN-SLOPE Rotary switch in the position (latched with slope) Changeover switch in the position (HF ignition on) secondary current Gas pre Gas post- Up-Slope Down-Slope flow time flow time Press 1st torch trigger Release 1st torch trigger Press 1st torch trigger Release 1st torch trigger...

  • Page 18: Mma Welding

    Function specification 2nd step • Release the torch trigger. • The welding current increases with the gradient set (UP-SLOPE) to the welding current I With the second torch trigger, it is possible to switch to the secondary current operating point I during welding.
  • Page 19 Function specification This machine has the following features in MMA operation: • Arcforcing Shortly before the electrode threatens to stick, the arcforcing device sets an increased current designed to prevent the electrode from sticking. The value of the increased current depends on the welding voltage and the setting on the arcforcing rotary dial (Chap.

  • Page 20: Remote Controls

    Function specification Remote controls Only the remote controls described in these operating instructions may be connected! Plug the remote control into the remote control socket of the welding machine (Chap. 2, D2) and lock it only when the machine is switched off. The remote control is detected automatically when the welding machine is switched on.
  • Page 21 Function specification Manual remote control FRP 10 Functions: • Pulse / spot (changeover switch on the remote control). • Pulse / spot and break times infinitely adjustable (2 rotary dials on the remote control). Pulse current corresponds to the welding current I Break current corresponds to the secondary current I (set on the welding machine).

  • Page 22: Interface For Mechanised Welding (Remote Control Connection Socket)

    Function specification Interface for mechanised welding (remote control connection socket) The welding current sources feature a very high standard of safety. This high safety standard is also retained when peripheral equipment is connected for automated welding if this peripheral equipment fulfils the same criteria, particularly with regard to its isolation from the mains supply.
  • Page 23 inverter TIG 150-300 DC (follow safety instructions) Preparations Adjustment Fault elimination • Select ignition current Is (% of I1). Plug in the mains cable. No HF ignition: • Set toggle switch to HF position. (Remember fuse!) 100% • Insert workpiece lead, lock and attach UP-SLOPE •...

  • Page 24: Commissioning

    Commissioning Setting up the welding machine Follow safety instructions on the opening pages entitled “For Your Safety”. • Set up the machine so that there is enough room to adjust the operating elements. • Ensure that the machine is set up in a stable position and appropriately secured. Mains connection The correct mains plug must be attached to the mains supply lead of the machine.

  • Page 25: Welding Machine Cooling System

    Commissioning Welding machine cooling system Observe the following to attain the optimum duty cycle of the power components: • Ensure that the working area is adequately ventilated, • Do not obstruct the machine’s air inlets and outlets, • Metal parts, dust or other foreign bodies must not get into the machine. Workpiece lead Remove paint, rust and dirt from clamping and welding areas with a wire brush! Attach the workpiece clamp in the immediate vicinity of the welding position! Structural parts, pipes,...

  • Page 26: Tig Welding Torch Connection

    Commissioning 5.6.1 TIG welding torch Prepare welding torch according to the welding task in hand (see operating instructions of the torch). • Plug the torch trigger plug into the socket (Chap. 2, E and tighten. • Engage the rapid-action closure nipple of the TIG torch in the rapid-action closure coupling for the coolant supply (blue) and return (red) lines (only for water-cooled torches).

  • Page 27: Currentless Testing And Setting The Amount Of Shielding Gas

    Commissioning 5.7.2 Currentless testing and setting the amount of shielding gas Consequences of incorrect shielding gas settings: Insufficient shielding gas: inadequate gas protection, the indrawn air leads to pores in the weld seam. Excessive shielding gas: turbulence may occur, as a result of which air can penetrate and lead to pores in the weld seam.

  • Page 28: 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 29: Repair Work

    Maintenance and care 7.2.2 Measurement of protective conductor resistance Measure between safety contact of the mains plug and metal parts which can be touched, e.g. casing screws. During measuring, the entire length of the machine’s connection lead, especially near the connection points, must be moved. The resistance must be <...

  • Page 30: Operating Problems, Causes And Remedies

    Operating problems, causes and remedies 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 process chart. If none of the fault elimination procedures described leads to the correct functioning of the machine, please inform your authorised dealer.

  • Page 31: Customer Checklist Inverter Tig 200 Dc Powersinus

    Operating problems, causes and remedies inverter powerSinus 8.1.2 Customer checklist ( TIG 200 DC Switch on the machine (at the mains switch (Kap. 2, A) • Mains supply broken • Mains plug not inserted Machine functioning • Mains fuse faulty •...
  • Page 32 Operating problems, causes and remedies inverter 8.1.3 Customer checklist ( TIG 250 und 300 DC ) Switch on the machine (at the mains switch (Kap. 2, A) • Mains supply broken • Mains plug not inserted Machine functioning • Mains fuse faulty •...
  • Page 33 Ersatzteilliste / Spare parts list inverter inverter powerSinus Abb. 11 Vorderseite TIG 150 DC TIG 200 DC inverter inverter powerSinus Fig. 11 Front view TIG 150 DC TIG 200 DC inverter inverter Abb. 12 Vorderseite TIG 250 DC und TIG 300 DC inverter inverter Fig.
  • Page 34 Ersatzteilliste / Spare parts list inverter inverter inverter Pos. Bezeichnung: Type TIG150DC TIG200DC TIG250DC powerSinus inverter TIG300DC ∅ 31mm Drehknopfdeckel 074-000234-00001 Knob cover ∅ 31mm Drehknopf Pfeilscheibe 074-000234-00002 Arrow indicator ∅ 31mm Drehknopf 074-000234-00000 Knob Bedienungsseite mit INTIG 03 092-000315-00000 Operating side with INTIG 03 Leiterplatte WIG –...

  • Page 35: Tig 250 And 300 Dc

    Ersatzteilliste / Spare parts list inverter inverter powerSinu Abb. 13 Rückseite TIG 150 DC und TIG 200 DC inverter inverter powerSinus Fig. 13 Rear view TIG 150 DC and TIG 200 DC inverter inverter Abb. 14 Rückseite TIG 250 DC und TIG 300 DC inverter inverter...
  • Page 36 Ersatzteilliste / Spare parts list inverter inverter inverter Pos. Bezeichnung: Type TIG150DC TIG200DC TIG250DC powerSinus inverter TIG300DC Magnetventil 1/4" 074-000227-00000 Solenoid valve Hauptschalter 074-000231-00000 Main switch Netzkabel 074-000236-00001 074-000236-00001 094-000002-00000 Mains cable Schalter 044-001939-00000 044-001939-00000 Toggle switch Sicherung träge 094-000202-00000 094-000202-00000 Fuse slow-blowing...
  • Page 37 Ersatzteilliste / Spare parts list inverter Abb. 15 Linke Seite TIG 150 DC inverter Fig. 15 Left hand side TIG 150 DC inverter powerSinus Abb. 16 Linke Seite TIG 200 DC inverter powerSinus Fig. 16 Left hand side TIG 200 DC inverter inverter Abb.
  • Page 38 Ersatzteilliste / Spare parts list inverter inverter inverter Pos. Bezeichnung: Type TIG150DC TIG200DC TIG250DC powerSinus inverter TIG300DC PCB Schutzbeschaltung DSB5/1 040-000448-00000 PCB protactive wiring Sekundär SKD6xD370-04F 072-000330-00000 Dioden Kühler 6xD70-04F Zündgerät HF-DC1/42 040-000309-00000 Ignition unit 070-000019-00000 Inverterbausatz WIG DC26V/150A 220V-S Inverter kit 070-000040-00000 WIG DC28V/200A 230/240V-S...
  • Page 39 Ersatzteilliste / Spare parts list inverter Abb. 18 Rechte Seite TIG 150 DC inverter Fig. 18 Right hand side TIG 150 DC inverter powerSinus Abb. 19 Rechte Seite TIG 200 DC inverter powerSinus Fig. 19 Right hand side TIG 200 DC inverter inverter Abb.
  • Page 40 Ersatzteilliste / Spare parts list inverter inverter inverter Pos. Bezeichnung: Type TIG150DC TIG200DC TIG250DC powerSinus inverter TIG300DC PCB Sperrwandler SPW3/2 040-000474-00000 PCB blocking converter PCB Haupt- 040-000451-00000 TRSQW3/200/1 regelungselektronik TRDC2/250/6 040-000290-00015 TRDC2/300/2 040-000290-00018 PCB main regulator electr.onic Durchflußwandler DC 5.0/220V-02 072-000347-00000 Netzgleichrichter B2 35/12...

  • Page 41: Accessories

    Zubehör 10.1 Torches / electrode holders Description Designation Article No. Electrode holder with 4 m cable 50 mm EH 50 092-000004-00000 Electrode holder with 4 m cable 70 mm EH 70 092-000011-00000 Workpiece lead with 4 m cable 50 mm and clamp WK50QMM-4M/K 092-000003-00000...

  • Page 42: Hf Pulse Generator Hf-Dc1/42 And Zgp1/8.0-4

    HF pulse generator HF-DC1/42 and ZGP1/8.0-42 Before all work on the pulse generator, switch off the supply voltage and remove the mains plug! Repairs by electricians only. 11.1 Technical data Type HF pulse generator HF-DC 1/42 ZGP 1/8.0-42 Nominal input voltage 42VAC 42VAC Permissible deviation...

  • Page 43: Inverter Tig 200 Dc

    Instruction Manual for Power Cooler Air Blast 12.1 Description of Unit The power cooler is used for recirculating and cooling welding torch coolant. The cooling unit is fitted with an Air Blast heat exchanger, therefore the efficiency of the cooling unit is affected directly by the ambient temperature.

  • Page 44: Commissioning

    Instruction Manual for Power Cooler Air Blast Quick release coupling, coolant return from welding torch Quick release coupling, coolant supply to welding torch Viewing window (coolant level) Filler inlet coolant (with screwcap lid and sieve) Current overload cut-out for coolant pump 12.4 Commissioning Please read the safety information on pages 3 + 4 before proceeding further...

  • Page 45: 12.5 Spare Parts List

    Instruction Manual for Power Cooler Air Blast 12.5 Spare parts list: Fig 23: Fig 24: power power left hand side Kühlmodul Kühlmodul right hand side Fig 22: Front view power Cooler with inverter TIG 200 DC powerSinus power Cooler Pos. Description: Side panel (left) 094-001645-00005...

  • Page 46: Circuit Diagrams

    Schaltpläne / Circuit Diagrams inverter 13.1 TIG 150 DC (Schaltpläne befinden sich ebenfalls im Gerät) 13/1...
  • Page 47 Schaltpläne / Circuit Diagrams inverter powerSinus 13.2 TIG 200 DC 13/2...
  • Page 48 Schaltpläne / Circuit Diagrams inverter powerSinus power 13.3 TIG 200 DC Kühlmodul 13/3...
  • Page 49 Schaltpläne / Circuit Diagrams inverter 13.4 TIG 250/300 DC 13/4...

This manual is also suitable for:

Inverter tig 200 dc powersinusInverter tig 300 dcInverter tig 250 dc

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