Operating instructions

Transcription

1 EWM HIGHTEC WELDING GmbH Dr.-Günter - Henle - Straße 8; D Mündersbach Phone: +49 (0) ; Fax: +49 (0) Internet: ; info@ewm.de Operating instructions inverter TIG DC welding machines from 150A 300A portable inverter TIG 200 DC powersinus power Cooler inverter TIG 150 DC inverter TIG 250 DC inverter TIG 300 DC 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 ), the machines can be used in environments with an increased electrical hazard. ª 2000 We reserve the right to make amendments. Art. No.: EWM01 Revised:

2 Name des Herstellers: Name of manufacturer: Nom du fabricant: Anschrift des Herstellers: Address of manufacturer: Adresse du fabricant: Hiermit erklären wir, daß das nachstehend bezeichnete Gerät in seiner Konzeption und Bauart sowie in der von uns in Verkehr gebrachten Ausführung den grundlegenden Sicherheitsanforderungen der unten genannten EG- Richtlinien entspricht. Im Falle von unbefugten Veränderungen, unsachgemäßen Reparaturen und / oder unerlaubten Umbauten, die nicht ausdrücklich von EWM autorisiert sind, verliert diese Erklärung ihre Gültigkeit. Gerätebezeichnung: Description of the machine: Déscription de la machine: Gerätetyp: Type of machine: Type de machine: EG - Konformitätserklärung EU - conformity declaration Déclaration de Conformidité de U.E. EWM HIGHTEC WELDING GmbH (nachfolgend EWM genannt) (In the following called EWM) (nommé par la suite EWM) Originaldokument liegt jedem Gerät bei! Dr.- Günter - Henle - Straße 8 D Mündersbach Germany info@ewm.de We herewith declare that the machine described below meets the standard safety regulations of the EU- guidelines mentionned below in its conception and construction, as well as in the design put into circulation by us. In case of unauthorized changes, improper repairs and / or unauthorized modifications, which have not been expressly allowed by EWM, this declaration will lose its validity. Par la présente, nous déclarons que la conception et la construction ainsi que le modéle, mis sur le marché par nous, de l appareil décrit ci - dessous correspondent aux directives fondamentales de sécurité de la U.E. mentionnées ci- dessous. En cas de changements non autorisés, de réparations inadiquates et / ou de modifications prohibeés, qui n ont pas été autorisés expressément par EWM, cette déclaration devient caduque. Original document is enclosed with each machine! Artikelnummer EWM: Article number: Numéro d article Seriennummer: Serial number: Numéro de série: Optionen: Options: Options: Zutreffende EG - Richtlinien: Applicable EU - guidelines: Directives de la U.E. applicables: keine none aucune EG - Niederspannungsrichtlinie (73/23/EWG) EU - low voltage guideline Directive de la U.E. pour basses tensions EG- EMV- Richtlinie (89/336/EWG) EU- EMC guideline U.E.- EMC directive Document original est joint à toute machine! Angewandte harmonisierte Normen: Used co-ordinated norms: Normes harmonisées appliquées: EN / IEC / VDE 0544 EN / VDE 0544 Teil 206 Hersteller - Unterschrift: Signature of manufacturer: Signature du fabricant: Michael Szczesny, Geschäftsführer managing director gérant

3 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 1 Technical data... 1/1 1.1 Area of application... 1/1 2 Operating elements... 2/1 3 Function specification logic control... 3/1 3.1 Logic control... 3/1 3.2 Function sequence of TIG non-latched operation without UP/DOWN-SLOPE... 3/5 3.3 Function sequence of TIG non-latched operation with UP/DOWN-SLOPE... 3/6 3.4 Function sequence of TIG latched operation with UP/DOWN-SLOPE... 3/7 3.5 MMA welding... 3/8 3.6 Remote controls... 3/ Interface for mechanised welding (remote control connection socket)... 3/12 4 Quick start the shortest way to welding... 4/1 Inhalt/1

4 Table of Content Page 5 Commissioning... 5/1 5.1 Setting up the welding machine... 5/1 5.2 Mains connection... 5/ Switching the control transformer to 415V mains voltage... 5/1 5.3 Welding machine cooling system... 5/2 5.4 Workpiece lead... 5/2 5.5 Electrode holder (MMA welding)... 5/2 5.6 General information on connection of the TIG welding torch... 5/ TIG welding torch connection... 5/ TIG potentiometer welding torch connection... 5/3 5.7 Shielding gas supply... 5/ Establishing the gas connections... 5/ Currentless testing and setting the amount of shielding gas... 5/4 6 Adjustment instructions (pending)... 5/4 7 Maintenance and care... 7/1 8 Operating problems, causes and remedies... 8/1 8.1 Customer checklist inverte r TIG 150 DC... 8/1 8.2 Customer checklist inverter TIG 200 DC powersinus... 8/2 8.3 Customer checklist inverter TIG 250 and 300 DC... 8/3 9. Spare parts list... 9/1 10. Accessories... 10/1 11. HF pulse generator HF-DC1/42 and ZGP1/ /1 12 Instruction Manual for Power Cooler Air Blast Cooler Unit for a inverter TIG 200 DC powersinus... 12/ Description of Unit... 12/ Technical Data... 12/ Operating Elements Front and Rear Views of Power Cooler Module... 12/ Commissioning... 12/ Spare Parts List... 12/3 13. Circuit diagrams... 13/1 Inhalt/2

5 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 The machine may only be connected to correctly earthed sockets. Only operate with intact connection lead including protective conductor and safety plug. An improperly repaired plug or damaged mains cable insulation can cause electric shocks. The machine may only be opened by qualified and authorised personnel. Before opening, pull out the mains plug. Switching off is not sufficient. Wait for 2 minutes until capacitors are discharged. Always put down welding torch, stick electrode holder in an insulated condition. Even touching low voltages can cause you to jump and lead to accidents, so: Safeguard yourself against falls, e.g. from a platform or scaffolding. When welding, operate earth tongs, torch and workpiece properly, not in ways for which they are not intended. Do not touch live parts with bare skin. Only replace electrodes when wearing dry gloves. Never use torches or earth cables with damaged insulation. 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. Workpiece, flying sparks and droplets are hot Keep children and animals well away from the working area. Their behaviour is unpredictable. Move containers with inflammable or exposive liquids away from the working area. There is a danger of fire and explosion. Never heat explosive liquids, dusts or gases by welding or cutting. There is also a danger of explosion if apparently harmless substances in closed containers are able to build up excess pressure when they are heated. Take care to avoid fire hazards Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying, when parts are glowing or hot slag is present. A constant check must be kept on whether fire hazards have been created in the working area. Highly inflammable objects, such as matches and cigarette lighters for example, must not be carried in trouser pockets. You must ensure that fire extinguishing equipment - appropriate to the welding process - is available close to the welding work area and that easy access is possible. Safety /1

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. Loose welding connections can completely destroy protective conductor systems of interior installations and cause fires. Before beginning welding work, ensure that the earth tongs are properly fixed to the workpiece or welding bench and that there is a direct electrical connection from the workpiece to the power source. Noise exceeding 70 dba can cause permanent hearing damage Wear suitable earmuffs or plugs. Ensure that other people who spend time in the working area are not inconvenienced by the noise. Secure gas cylinder Place shielding gas cylinders in the holders provided for them and secure with safety chains. Take care when handling cylinders; do not throw or heat, guard against them toppling over. When moving by crane, take off the gas cylinder from the welding machine. Caution: 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. The functioning of heart pacemakers can be adversely affected when you are standing near the welding machine. Malfunctioning of electronic equipment (e.g. EDP, CNC equipment) in the vicinity of the welding location is possible. Other mains supply leads, trip leads, signal and telecommunications leads above, under and near the welding device may be subject to interference. Warning: Electromagnetic interference must be reduced to such a level that it no longer constitutes interference. Possible reduction measures: Welding machines should be regularly maintained (see Sect. Maintenance and care ) Welding leads should be as short as possible and run closely together on or near to the ground. Selective shielding of other leads and equipment in the environment can reduce radiation. Caution: Repairs and modifications may only be carried out by authorised, trained, specialist personnel. The warranty becomes null and void in the event of unauthorised interference. Our operating instructions will provide you with an introduction into the safe use of the machine. Therefore please read them closely and only start work when you are familiar with them. Safety /2

7 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. Environmental conditions: The welding machine can be operated in a location where there is no risk of explosion at an ambient temperature a relative air humidity of -10 C (plasma machines 0 C) to +40 C and up to 50% at 40 C. where the surrounding air is free of unusual amounts of dust, acids, corrosive gases or substances etc., insofar as they do not occur during welding. Examples of unusual operating conditions: Unusual corrosive smoke, vapour, excessive oil vapour, unusual vibrations or jolts, excessive quantities of dust such as grinding dust etc., severe weather conditions, unusual conditions near the coast or on board ship. When setting up the machine, ensure that air inlets and outlets are unobstructed. The machine is tested to Protection Standard IP23, i.e.: Protection against penetration of solid foreign bodies > 12mm, Protection against water spray up to an angle of 60 to the vertical. Notes on the use of these operating instructions These operating instructions are arranged in Sections. To help you find your way around more quickly, in the margins you will occasionally see, in addition to sub-headings, icons referring to particularly important passages of text which are graded as follows depending on their importance: (Note): Applies to special technical characteristics which the user must note. (Warning): Applies to working and operating procedures which must be followed precisely to avoid damaging or destroying the machine. (Caution): Applies to working and operating procedures which must be followed precisely to avoid endangering people and includes the Warning symbol. Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet points, e.g.: Insert plug of welding current lead into socket (Sect. 5, G2) and lock. Meaning of the diagram descriptions: e.g. (C1) means: Item C / Figure 1 in the respective Section e.g. (Sect. 3, C1) means: in Section 3 Item C / Figure 1 Safety /3

8 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: Less effort in changing to another workplace because the machine dimensions and weight are substantially reduced. Lower power consumption and smaller mains ratings by high efficiency (no losses). No need for expensive compensating equipment by a high cos phi and a correspondingly smaller reactive current draw from the mains. Functional safety by robust construction, highly integrated electronic circuitry. High operating safety by thermal monitors in the power circuit. High control dynamics for the welding process. Therefore excellent welding and ignition results and absolute reproducibility of all welding parameters. Welding result independent of mains voltage fluctuations. Easily serviced design by the use of modern, modular technology. The powersinus Series: The machines with powersinus series have a built-in electronic switching unit which restricts the current spikes coming from the mains supply and produces a pure Sinus-form of mains current. As a result 200Amps welding current can be achieved from a 230V plug fused at 16Amps with a cos phi of 1. AL/1

9 1 Technical data inverter with S -sign Adjustable: Welding current TIG 150 DC TIG 200 DC powersinus TIG 250 DC TIG 300 DC 5A - 150A 5A - 200A 5A - 250A 5A - 300A Welding voltage 10,1V - 26V 10V - 28V 10V - 30V 10V - 32V Mains voltage (tolerances) Mains frequency Mains fuse slow-blow 1x230V (15%;-40%) 1x240V (10%;-40%) 1x230V (15%;-40%) 1x240V (10%;-40%) 3x400V (20%;-25%) 3x415V (15%;-25%) 3x400V (20%;-25%) 3x415V (15%;-25%) 50/60Hz 1 x 16A 1 x 16A 3 x 16A 3 x 16A Welding current TIG / MMA 25%duty cycle - / 150A - / 200A - / - - / - 35%duty cycle 150A / - 200A / - - / - - / - 40%duty cycle - / - - / - - / - 300A / 300A 60%duty cycle 116A / 97A 150A / 130A 250A / 250A 250A / 250A 100%duty cycle 90A / 75A 120A / 100A 190A / 190A 190A / 190A Load alternation 10min (60% duty cycle 6 min welding, 4min break) Workpiece 35mm 2 50mm 2 Open circuit voltage 100V 75V 106V 106V Efficiency 85% 89% cos phi 0,99 1,0 0,99 0,99 Ambient temperature -10 C bis +40 C Protection IP 23 classification Insulation class H Machine cooling fan Torch cooling gas Total weight 23kg 22kg 26kg 26kg Dimensions (LxBxH) 450x290x400mm 530x260x400mm 480x355x400mm 480x355x400mm Constructed to VDE 0544 und EN standards S All welding machines which carry the S marking are constructed in accordance with VDE 0544 (EN ) and can be used in working with increased hazard of electrical shock 1.1 Area of application: This machines are suitable exclusively for: TIG DC welding with HF and Liftarc ignition of all metals except aluminium. MMA DC welding. All welding machines which carry the S marking are constructed in accordance with VDE 0544 (EN ) and can be used in working with increased hazard of electrical shock 1/1

10 2 Operating elements H H L K A G B I F E J D C A K F B I G E J D C Fig. 1 inverter TIG 150 DC Fig. 2 inverter TIG 200 DC powersinus H F L K A G B I E J D C Fig. 3 inverter TIG 250 DC and inverter TIG300 DC Item Symbol Description A Mains ON/OFF Switch ( inverter TIG 200 DC powersinus at rear side) B + Welding cable connector positive + for work piece cable TIG and MMA welding C - Welding cable connector - ( for TIG- and MMA welding) D Gas connection G 1/4" with power connection Minus - with HF E Torch trigger connection socket (5 pole) F Control panel (see Chap. Logic control) G Remote control connection socket (14 pole) H Hand crib I Rubber feet J Air inlet openings K Air outlet openings (Rear side) L RUTIL BASISCH CELL Rotary 1 9 dial arcforcing device (only TIG 200/250/300) 0 10 ArcForce 2/1

11 3 Function specification 3.1 Logic control A1 E1 B1 F1 H1 C1 G1 I 1 UP-SLOPE DOWN-SLOPE I 2 50% % 0% 100% 0% 100% I S I 2 I sec. 20sec. GAS AMPERE T I1 K1 J1 D1 N1 L1 M1 Fig. 1: Logic control INTIG03 3/1

12 3 Function specification A1 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 B1 UP-SLOPE 0 25 MMA operating mode UP-SLOPE (current increase) The increase in current from the ignition current I s (E1) to the main current value I 1 (F1) can be infinitely adjusted between 0-25 sec with this rotary dial. Definition of UP-Slope and DOWN-Slope: Rise and fall times are set as angles, the maximum times of 25 sec are reached when Is = minimum and I1 maximum are selected. A change e.g. in the welding current I1 (broken line) results in a shortening of the UP-Slope and DOWN- Slope times. 3/2

13 3 Function specification C1 D1 E1 F1 DOWN-SLOPE sec. 20sec. GAS 50% 0% 100% I S I 1 DOWN-SLOPE (current fall) The fall in the main current I 1 (F1) to the end-crater current (minimum current) can be infinitely adjusted between 0-25 sec with this rotary dial. Gas post-flow time Selects the gas post-flow time between 0-20 sec. Note: The gas pre-flow time can be infinitely adjusted internally from s. Ignition current Setting of the ignition current I s (E1) in per cent of the main current I 1 (F1) (search arc in 0% position) Main current I 1 (welding current) For both TIG/plasma and stick electrode welding, the welding current I 1 can be infinitely adjusted with this rotary dial. DC operation 5A - maximum current G1 50% Secondary current 0% I 2 100% The secondary current I 2 (G1) is infinitely adjustable as a percentage of the main current I 1 (F1). During the welding process, it is possible to switch from the main current I 1 to the secondary current I 2 set at any time using the 2 nd torch trigger. H1 Green LED power unit On Lights when the power unit is switched on. I1 Yellow LED (excess temperature) Thermal monitors in the power unit trigger at excess temperature and the excess temperature indicator lamp lights. Welding can proceed without further measures after cooling. J1 Pre-selection switch (currentless test) When this toggle switch is in position T, the current source is in the "currentless T test" functioning mode. In this operating mode the power unit is blocked and the welding data and the UP- and DOWN-Slope times can be preset without the welding current. Note: Welding is impossible! Latched operating mode example: Torch trigger pressed (1 st step) Display: Ignition current I S Release torch trigger (2 nd step) Display runs up to the main current I 1 in the UP-Slope time set Press secondary current button Display: Secondary current I 2 Torch trigger pressed (3 rd step) Display runs down to the end-crater current DOWN-Slope time set Release torch trigger (4 th step) Display: Ignition current I S 3/3

14 3 Function specification K Digital ammeter Displays the welding current at all times. L1 M1 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. If the collective interference LED continues to be lit after an appropriate waiting time, see the chapter on troubleshooting. Red LED (water deficiency) Indicates a water deficiency in water-cooled welding machines. N1 Changeover switch for selecting the ignition modes HF HF ignition: In HF welding, the arc is initiated without contact by a high-voltage ignition pulse. HF Liftarc ignition: In welding with Liftarc ignition, on the other hand, the Tungsten electrode is in contact with the workpiece. The torch trigger is operated and a minimum current flows. The torch is now removed from the workpiece, the arc ignites and the welding current set flows according to the operating mode. 3/4

15 3 Function specification 3.2 Function sequence of TIG non-latched operation without UP/DOWN-SLOPE E1 Set the rotary switch to the position (non-latched without slope) N1 Set the changeover switch to 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. The welding current flows and immediately assumes the value set for the welding current I 1. HF is switched off. 2nd step: Release the torch trigger. The arc extinguishes. The gas post-flow time set begins. Fig. 2 Function sequence of non-latched operation without Slope 3/5

16 3 Function specification 3.3 Function sequence of TIG non-latched operation with UP/DOWN-SLOPE E1 Rotary switch in the position (non-latched with slope) N1 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. The welding current flows and immediately assumes the value set for the ignition current I s. HF is switched off. The welding current increases with the gradient set (UP-SLOPE) to the welding current I 1. 2nd step: Release the torch trigger. The welding current falls with the current gradient set (DOWN-SLOPE) to the end-crater current I E (minimum current). The welding current reaches the end-crater current I E the arc extinguishes. The gas post-flow time set begins. I 1 Welding current I E I S Gas pre flow time Up-Slope Down-Slope Gas postflow time t Press torch trigger (1st step) Release torch trigger (2nd step) Fig. 3 Non-latched function sequence with Slope 3/6

17 3 Function specification 3.4 Function sequence of TIG latched operation with UP/DOWN-SLOPE E1 Rotary switch in the position (latched with slope) N1 Changeover switch in the position (HF ignition on) I 1 Welding current secondary current I 2 I S I E Gas pre flow time Up-Slope Down-Slope Gas postflow time t Press 1st torch trigger (1st step) Release 1st torch trigger (2nd step) Press 1st torch trigger (3rd step) Release 1st torch trigger (4th step) Fig. 4 Latched function sequence 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. Welding current flows and immediately assumes the ignition current value set (search arc at minimum setting). HF is switched off. 3/7

18 3 Function specification 2nd step Release the torch trigger. The welding current increases with the gradient set (UP-SLOPE) to the welding current I 1. With the second torch trigger, it is possible to switch to the secondary current operating point I 2 during welding. 3rd step Operate the torch trigger. The welding current falls with the gradient set (DOWN-SLOPE) to the end-crater current I E (minimum current). 4th step Release the torch trigger. The arc extinguishes. The gas post-flow time set begins. It is also possible to terminate the welding procedure immediately without DOWN-SLOPE and end-crater current By briefly operating the 1 st torch trigger (3 rd step). The current falls to zero and the gas post-flow time begins. Automatic cut-out: In latched operating mode, if no ignition of the arc occurs after operation and release of the torch trigger or if the arc is interrupted when the torch is moved away, an automatic cut-out occurs within 3 sec. The HF, gas and open circuit voltage (power unit) are switched off. 3.5 MMA welding E1 Rotary switch in the position (electrode) F1 Select welding current I 1 (5A - maximum current). I 1 If welding is performed alternately by different methods, e.g. TIG or MMA, and if a welding torch 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. 3/8

19 3 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. 2, item L). "Far left" position: Low arcforcing gentle arc, little increased current before short-circuit. Used with stick electrodes enveloped with rutile. "Centre" position: Moderate arcforcing normal arc, moderate increased current before short-circuit. Used with stick electrodes enveloped with basic material. "Far right" position: High arcforcing severe arc, high increased current before short-circuit. Used with cellulose stick electrodes. Automatic hotstart device Brief increase in the welding current during ignition time in the millisecond range. Hotstart The hotstart current is infinitely adjustable from the minimum to the main current I 1 and the hotstart time from 0-2 sec with the additional remote control FR 35. The hotstart device makes it possible to ignite and re-ignite critical stick electrodes without difficulty. Antistick If the stick electrode sticks in spite of the arcforcing device, the machine automatically switches over to the minimum current within about 1 sec, so that overheating of the electrode is prevented. If the antistick device has responded, check the welding current setting and if necessary correct it. 3/9

20 3 Function specification 3.6 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. See the operating instructions of the remote control for detailed information. Foot-operated remote control FR 21 Functions: Welding current "ON/OFF" (switches on after the pedal has been operated). Infinitely adjustable welding current (in %) depending on the main current I 1 selected on the welding machine. Commissioning: Plug the remote control into the remote control socket of the welding machine or of the FRA 40 before switching on the welding machine. Manual remote control FR 30 Functions: Infinitely adjustable welding current (in %) depending on the welding current I 1 selected on the welding machine. Commissioning: Plug the remote control into the remote control socket of the welding machine or of the FRA 40 before switching on the welding machine. Manual remote control FRA 40 Functions: The welding current I 1 is adjustable in absolute values from the minimum to the maximum current (regardless of the welding current selected on the machine) The machine can be switched from remote control FRA 40 (switch position up) to another remote control (switch position down) with the changeover switch. Commissioning: Plug the remote control into the remote control socket of the welding machine before switching on the welding machine. Adjust the measurement range of the welding current display to the maximum current of the machine. (DIP toggle switch in the remote control, setting when supplied: 250A) Special features: LED welding current display. 10-turn helical potentiometer for accurate setting of welding current. Connection facility for further remote controls. 3/10

21 3 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 1. Break current corresponds to the secondary current I 2 (set on the welding machine). Commissioning: Plug the remote control into the remote control socket of the welding machine before switching on the welding machine. Switch the operating mode selector switch on the welding machine to latched operation. Special features: Connection facility for remote control FR 21 or FR 30. Manual remote control FRP 15 Functions: Remote control "ON/OFF" (changeover switch on the remote control). Pulses "ON/OFF" (changeover switch on the remote control). Pulse and break time infinitely adjustable (2 rotary dials on the remote control). Pulse current I 1 (on the remote control) is set as a percentage of the welding current I 1 selected (on the welding machine). Break current corresponds to the secondary current I 2 (set on the welding machine). Commissioning: Plug the remote control into the remote control socket of the welding machine before switching on the welding machine. Switch on the remote control. Switch the operating mode selector switch on the welding machine to latched operation. Special features: Connection facility for remote control FR 21. Manual remote control Hotstart FR 35 Functions: Remote control "ON/OFF" (changeover switch on the remote control). Hotstart current and hotstart time infinitely adjustable. The welding current I 1 is adjustable in absolute values from the minimum to the maximum current, that is to say regardless of the welding current selected on the machine. Commissioning: Plug the remote control into the remote control socket of the welding machine before switching on the welding machine. Switch on the remote control. Special features: Connection facility for remote control FRA 40. 3/11

22 3 Function specification 3.7 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. This is ensured by the use of transformers according to VDE The welding machines are equipped for automated operation as standard. Galvanically isolated relay contacts (galvanically isolated) and control inputs are available at the remote control connection socket (Chap. 2, G) of the current source for automated applications. Interface for mechanised welding (EB3) 14-pole connection socket (Chap. 2, G) on the front of the current source: External nominal value of the user Torch trigger control signal Current relay contact to the user (galvanically isolated), maximum load: 100mA, +-15V Connection for cable screen Current supply +/- 15V Choice of "Internal" / "External" nominal value input Fig. 5 Interface for mechanised welding EB3 3/12

23 4.1 inverter TIG DC (follow safety instructions) Preparations Adjustment Fault elimination Plug in the mains cable. (Remember fuse!) + Insert workpiece lead, lock and attach conductively to the workpiece. 50% 0% 100% I S UP-SLOPE Select ignition current Is (% of I1). No HF ignition: Set toggle switch to HF position. Set current raising time to I1. No welding current Workpiece lead in "-" socket. Connect welding torch 0 25 Set welding current I1 (max. value for remote control). Excess temperature LED lights: Duty cycle exceeded > allow machine to cool I 1 Establish the torch control connection with the Tuchel plug. Plug in the remote control connector plug 0% 50% I 2 100% DOWN-SLOPE Select secondary current I 2 (% of I 1 ) with 2 nd torch trigger. Time of current fall to minimum current 5A Other faults: Fault inside the machine > notify the service department 0 25 Establish the shielding gas supply, open pressure reducer Set the gas post-flow time. Switch on machine. 0sec. 20sec. GAS Preset with "no-power test" key button and check torch trigger. Select the operating mode. RUTIL T green BASISCH CELL Welding current flows: signal light lights, does not light > see fault elimination. For electrode welding: 8 Set arcforcing ArcForce 4/1

24 5 Commissioning 5.1 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. 5.2 Mains connection The correct mains plug must be attached to the mains supply lead of the machine. The connection must be made by an electrician in compliance with current VDE regulations. The phase sequence is irrelevant! The operating voltage shown on the rating plate must be consistent with the mains voltage! For mains fuse protection, please refer to the "Technical data" section. Insert mains plug of the switched-off machine into the appropriate socket Reconnecting the mains voltage 400/415V at the control transformer The Faston plug (arrow) must be set on the transformer according to the mains voltage. For 400V: Plug to pin 3 (works setting), For 415V: Plug to pin V 400V 0V Fig.: Control transformer Machines delivered to countries with mains voltages which deviate from the standard are marked with the following labels: a) Indication of the mains voltage (at the end of the cable) b) Mains voltage on delivery (rear of the machine above the rating plate) Netzanschlußspannung 400V Mains voltage c) Special voltages, for marking according to rewiring on site (enclosed with the operating instructions) After rewiring for 415V, label c) must be taped over label b) and label a) must be removed from the end of the cable. 230V 230V 400V 400V c) 415V 415V 460V 460V 500V 500V V V (Art. No. label, see Chap. Accessories) 5/1

25 5 Commissioning 5.3 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. 5.4 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, rails etc. may not be used as return leads for the welding current if they are not the workpiece themselves! A perfect current connection must be ensured where welding benches and appliances are concerned. Insert cable plug of the workpiece lead into the welding current socket (Chap.2, B) and lock by turning to the right. MMA welding: The polarity depends on the instructions of the electrode manufacturer on the electrode packaging. 5.5 Electrode holder connection (MMA welding) Insert cable plug of the stick electrode holder into the welding current socket "+" (Chap. 2, B) or "-" (Chap. 2, C") and lock by turning to the right. The polarity depends on the instructions of the electrode manufacturer on the packaging. 5.6 General information on connection of the welding torch We can only guarantee the perfect functioning of our machines when they are used with our range of welding torches. TIG welding torches with a shielded torch trigger control line should not be connected! 1. The welding machines are supplied as standard with torch trigger pin assignment B1 and gas connection G1/4" (only decentralised). Fig. 2: Fig. 3 Torch trigger variations Connection socket connection B1 Torch trigger "BT" on PIN 1 / 2 Secondary current "I1 / I2" on PIN 1 / 3 5/2

26 5 Commissioning 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). Decentralised: Plug the welding current cable (if it exists) into the socket (Chap. 2, C) and lock by turning to the right. Screw the gas connection tightly to the connecting nipple G¼ (Chap. 2, D) (welding current potential - ). Central: Plug the central connecting plug into the central connection socket and tighten with the box nut TIG potentiometer welding torch The welding machine must be equipped with the "potentiometer torch connection facility" option to be able to operate a TIG potentiometer welding torch (if necessary fit "ASM potentiometer" option, see Accessories Chap.). 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. Plug the control cable plug into the socket (Chap.2, G) and tighten. Engage the rapid-action closure nipple of the torch in the rapid-action closure coupling for the coolant supply (blue) and return (red) lines (only for water-cooled torches). Decentralised: Plug the welding current cable (if it exists) into the socket (Chap. 2, C) and lock by turning to the right. Screw the gas connection tightly to the connecting nipple G¼ (Chap. 2, D) (welding current potential - ). Central: Plug the central connecting plug into the central connection socket and tighten with the box nut. 5.7 Shielding gas supply Establishing the gas connections Place the shielding gas cylinder in the cylinder holder and secure it against accidents with the securing chain! No impurities must be allowed to enter the shielding gas supply, as these would otherwise cause blockages. Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to blow out any dirt present. All shielding gas connections must be gastight! Mount the pressure reducer on the gas cylinder valve. Screw the gas hose gastight to the pressure reducer and connecting nipple G ¼" on the rear of the welding machine. 5/3

27 5 Commissioning 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. Switch on the machine at the main switch (Chap.2, A). Select latched operation mode with the program selector switch (Chap. 3, A1). Switch on the changeover switch (currentless test) (Chap. 3, J1) (position T) Press and release the torch trigger. Slowly open the gas cylinder valve. Allow the currentless test to proceed, and if necessary correct the welding current, UP-Slope DOWN-Slope, secondary current etc. Set the required amount of shielding gas on the pressure reducer, about 4 15 l/min depending on the current strength and the material. Switch off the pre-selection switch (currentless test) (position 0) The machine is now ready for welding! 6 Adjusting instructions in working 5/4

28 7 Maintenance and care D 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. Cleaning, testing and repairing of the welding machines may only be carried out by competent personnel. In the event of failure to comply with any one of the following tests the machine must not be operated again until the fault has been rectified. 7.1 Cleaning GB F Die im Kapitel "Wartung und Pflege" aufgeführten Hinweise, Richtlinien und Normen wurden grundlegend überarbeitet und sind aus diesem Grund nicht mehr gültig! Die relevanten Hinweise, Richtlinien und Normen finden Sie in den beiliegenden Ergänzungsblättern "Allgemeine Hinweise zu 3 Jahre Garantie", Art. Nr.: GAR-EWMxx. Sollten die Dokumente nicht vorliegen, können diese über den autorisierten Fachhändler angefordert werden! Außerachtlassung kann lebensgefährlich sein! The instructions, guidelines and standards given in the "Maintenance and Care" chapter have been completely revised and are therefore no longer valid! The relevant instructions, guidelines and standards can be found in the enclosed supplements "General notes on the 3 year warranty",item no.: GAR-EWMxx. If these documents are missing, they can be requested from your authorised specialist dealer! To do this, carefully disconnect the machine from the mains. PULL OUT THE MAINS PLUG! (Switching off or unscrewing the fuse is not adequate isolation). Wait for 2 minutes until the capacitors have discharged. Remove the casing cover. The individual components should be handled as follows: Current source Depending on the amount of dust, blow out current source using oil- and moisture-free compressed air. Electronics, circuit boards Do not blow on electronic components or circuit boards with the compressed air stream but suck clean using a vacuum cleaner. Not observing these instructions can be potentially fatal! Les consignes, directives et normes indiquées au chapitre «Maintenance et entretien» ont été mises à jour et ne sont donc plus valables! Vous trouverez les consignes, directives et normes applicables dans les additifs «Consignes générales relatives à la garantie de 3 ans», à l article : GAR-EWMxx. Si vous ne possédez pas les documents, vous pouvez vous les procurer auprès de votre revendeur autorisé! Le non-respect des consignes peut représenter un danger de mort! 7.2 Repetition test according to VDE 0702 and VBG 15 The following description of the repetition test is merely an extract from the detailed test instructions. If required, a copy can be requested from us. You are recommended to carry out a quarterly and an annual check. The annual test should also be carried out after every repair. Test sequence: Quarterly test: I Annual test: 1. Visual check of correct condition 2. Measurement of protective conductor resistance 1. Visual check of correct condition 2. Measurement of protective conductor resistance 3. Measurement of insulation resistance following internal cleaning of the power source 4. Measurement of open circuit voltage 5. Function test of the welding machine Le istruzioni, direttive e norme presenti nel capitolo Manutenzione e cura sono state completamente riviste e per questo motivo non sono più valide! Le istruzioni, direttive e norme rilevanti le trovate nell'aggiornamento qui allegato Istruzioni generali sui 3 anni di garanzia, Nr. Art.: GAR-EWMxx. Se i documenti non fossero disponibili, possono essere richiesti al rivenditore autorizzato! L'inosservanza delle istruzioni può comportare pericolo di vita! Visual check of correct condition The machine must be inspected for externally visible faults (without opening the machine). During this inspection, attention must be paid, for example, to the following points: External faults in mains plug and mains cable, e.g. insulation faults, scorch or pressure marks. Defects in anti-kink protection and the strain relief of the connection lead, mains switch. Faults in welding leads, tube package, plug fixture, arc torch. Signs of an overload and improper use. Damage to stop points and casing. Improper interference and modifications. The type plate and warning symbol must be present and legible. 7/1

29 7 Maintenance and care 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 < 0.1Ω. The measurement must be performed using at least 200 ma Measurement of insulation resistance The machine must be disconnected from the mains. Open the welding machine and clean carefully as described in Chap Switch on mains switch. Insulation resistance mains current circuit - casing: Measure from a connection of the mains plug to the casing. The resistance must be > 2.5 MΩ. Insulation resistance welding current circuit - casing: Measure between a welding socket and protective conductor. The resistance must be > 2.5 MΩ. Insulation resistance mains current circuit - welding current circuit: Measure from a connection of the mains plug to a welding current socket. The resistance must be > 5.0 MΩ Measurement of open circuit voltage (according to EN / VDE 0544 T1) + Input - Meqsurement circuit for peak values 1k0 Diode similar 1N k2 10nF 6u8F 0...5k V Connect the measuring circuit to the welding current sockets as shown in Fig. 1. The voltmeter must indicate the mean value. Adjust the potentiometer from 0kΩ to 5kΩ during the measurement. The measured voltage must not deviate from that specified on the rating plate (U 0 ) by more than 10% Function test of the welding machine Carry out a function test depending on the type of machine. 7.3 Repair work Repair and maintenance work may only be performed by specialist staff. In all service matters, always consult your dealer. Return deliveries of defective equipment subject to warranty may only be made through your dealer. When replacing parts, use only original spare parts. When ordering spare parts, the machine type, serial number and item number of the machine, as well as the type description and item number of the spare part must be quoted. If repair or maintenance work is carried out on this machine by personnel who are not trained and authorised to undertake such work, the right to claim under the warranty lapses. 7/2

30 8 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. 8.1 Customer checklist Customer checklist ( inverter TIG 150 DC) Switch on the machine (at the mains switch (Kap. 2, A) Machine functioning No Mains supply broken Mains plug not inserted Mains fuse faulty Mains power switch faulty Press torch trigger Green LED lights (Kap. 3, H1) power unit / "on" Shielding gas is expelled No Torch connection incorrect (check torch lead according to circuit diagram) Torch control cable not inserted Torch or torch trigger faulty No No shielding gas connected Pressure reducer turned off No Test switch (Kap. 3, J1) in test position Open circuit voltage (Option) yellow LED (Kap. 3, I1) excess temperature lights (allow machine to cool down) HF is applied No HF toggle switch on Lift-Arc ignition No Welding torch faulty Welding current Workpiece lead connected Workpiece lead in wrong socket Leaky shielding gas supply No Welding torch damaged Good welding properties Tungsten electrode contaminated insufficient or excessive shielding gas No Remote control plug not inserted in the Remote control functions machine Remote control or cable defective 8/1

31 8 Operating problems, causes and remedies Customer checklist ( inverter TIG 200 DC powersinus ) Switch on the machine (at the mains switch (Kap. 2, A) Machine functioning No Mains supply broken Mains plug not inserted Mains fuse faulty Mains power switch faulty Mains plug wrongly connected Press torch trigger Green LED lights (Kap. 3, H1) power unit / "on" Shielding gas is expelled No Torch connection incorrect (check torch lead according to circuit diagram) Torch control cable not inserted Torch or torch trigger faulty No No shielding gas connected Pressure reducer turned off No Test switch (Kap. 3, J1) in test position Open circuit voltage (Option) yellow LED (Kap. 3, I1) excess temperature lights (allow machine to cool down) HF is applied No HF toggle switch on Lift-Arc ignition No Welding torch faulty Welding current Workpiece lead connected Workpiece lead in wrong socket Leaky shielding gas supply No Welding torch damaged Good welding properties Tungsten electrode contaminated insufficient or excessive shielding gas No Remote control plug not inserted in the Remote control functions machine Remote control or cable defective 8/2

32 8 Operating problems, causes and remedies Customer checklist ( inverter TIG 250 und 300 DC) Switch on the machine (at the mains switch (Kap. 2, A) Machine functioning No Mains supply broken Mains plug not inserted Mains fuse faulty Mains power switch faulty Mains plug wrongly connected Press torch trigger Green LED lights (Kap. 3, H1) power unit / "on" Shielding gas is expelled No Torch connection incorrect (check torch lead according to circuit diagram) Torch control cable not inserted Torch or torch trigger faulty No No shielding gas connected Pressure reducer turned off No Test switch (Kap. 3, J1) in test position Open circuit voltage (Option) yellow LED (Kap. 3, I1) excess temperature lights (allow machine to cool down) HF is applied No HF toggle switch on Lift-Arc ignition No Welding torch faulty Welding current Workpiece lead connected Workpiece lead in wrong socket Leaky shielding gas supply No Welding torch damaged Good welding properties Tungsten electrode contaminated insufficient or excessive shielding gas No Remote control plug not inserted in the Remote control functions machine Remote control or cable defective 8/3

33 9 Ersatzteilliste / Spare parts list Abb. 11 Vorderseite inverter TIG 150 DC und inverter TIG 200 DC powersinus Fig. 11 Front view inverter TIG 150 DC and inverter TIG 200 DC powersinus Abb. 12 Vorderseite inverter TIG 250 DC und inverter TIG 300 DC Fig. 12 Front view inverter TIG 250 DC and inverter TIG 300 DC 9/1

34 9 Ersatzteilliste / Spare parts list Pos. Bezeichnung: Type inverter TIG150DC inverter TIG200DC powersinus inverter TIG250DC inverter TIG300DC 1 Drehknopfdeckel Knob cover 2 Drehknopf Pfeilscheibe Arrow indicator 3 Drehknopf Knob 4 Bedienungsseite mit INTIG 03 Operating side with INTIG 03 Leiterplatte WIG Steuerung PCB TIG control IC PAL IC PAL 5 Gehäuseabdeckung Casing panel 6 Halterung für Griffstange Hand grip mount 7 Griffstange Hand grip 8 Anschlußbuchse 14 polig Connection socket 14-pole Entstörplatine PCB interf. suppression 9 Anschlußbuchse Connection socket 10 Anschlußnippel Connection nipple 11 Schweißstrombuchsen Welding current socket 12 Gummifüsse Rubber foot 13 Drehknopf Knob 14 Drehknopfdeckel Knob cover 15 Drehknopf Pfeilscheibe Arrow indicator 16 LED-Anzeige LED-display 17 Kippschalter Toggle switch 18 Schalter Toggle switch 19 Hauptschalter Main switch Schaltergriff Switch knob 20 PCB WIG-Steuerung AC PCB TIG control AC Seitenwand Side panel 21 Befestigungswinkel für Tragegurt Angle bracket, carrying strap 31mm mm mm INTIG03/ L8 D1INTIG EB1 EB3 LC4/1 LC3/ polig G 1/4" mm mm mm DVM1/ ACTIG03/ /2

35 9 Ersatzteilliste / Spare parts list Abb. 13 Rückseite inverter inverter TIG 150 DC und TIG 200 DC powersinu Fig. 13 Rear view inverter inverter TIG 150 DC and TIG 200 DC powersinus inverter Abb. 14 Rückseite TIG 250 DC und inverter TIG 300 DC Fig. 14 Rear view inverter TIG 250 DC and inverter TIG 300 DC 9/3

36 9 Ersatzteilliste / Spare parts list Pos. Bezeichnung: Type inverter TIG150DC inverter TIG200DC powersinus inverter TIG250DC inverter TIG300DC 1 Magnetventil 1/4" Solenoid valve 2 Hauptschalter Main switch 3 Netzkabel Mains cable 4 Schalter Toggle switch 5 Sicherung träge Fuse slow-blowing /4

37 9 Ersatzteilliste / Spare parts list Abb. 15 Linke Seite inverter TIG 150 DC Fig. 15 Left hand side inverter TIG 150 DC Abb. 16 Linke Seite inverter TIG 200 DC powersinus Fig. 16 Left hand side inverter TIG 200 DC powersinus Abb. 17 Linke Seite inverter TIG 250 DC und inverter TIG 300 DC Fig. 17 Left hand side inverter TIG 250 DC and inverter TIG 300 DC 9/5

38 9 Ersatzteilliste / Spare parts list Pos. Bezeichnung: Type inverter TIG150DC inverter TIG200DC powersinus inverter TIG250DC inverter TIG300DC 1 PCB Schutzbeschaltung PCB protactive wiring 2 Sekundär Dioden Kühler DSB5/ SKD6xD370-04F 6xD70-04F Zündgerät Ignition unit 4 Inverterbausatz Inverter kit 5 Shunt Shunt 6 Kabeldurchführung Cable bushing 7 Lüfter Fan 8 Versorgungstrafo Supply transformer 9 PCB WIG-Steuerung PCB TIG control IC PAL IC PAL 11 Primärschalter Primary switch 12 Primärschalter Primary switch HF-DC1/ WIG DC26V/150A 220V-S WIG DC28V/200A 230/240V-S WIG DC30V/250A 3x380V-S WIG DC32V/300A 3x400V-L A/60mV EI 84a/59VA/ V EI66a/21VA/230V V EI66a/24VA/ V INTIG03/ L8 D1INTIG INV 25/500 DI 70-04GF15 D 70-04GF15 INV40/ M INV45/ M INV40/ P INV45/ P 13 Durchflußwandler DC 3.9/220V-02 DW 7,5/3x380V PCB Treiberelektronik PCB driver electronic 15 Varistormodul Varistor module 16 PCB Sperrwandler PCB blocking converter 17 Netzgleichrichter Mains rectifier 18 Thyristor-Modul Thyristor module TRI 1/ SB460/ B2 35/12 B6 105/16 MT MTD55-14A /6

39 9 Ersatzteilliste / Spare parts list Abb. 18 Rechte Seite inverter TIG 150 DC Fig. 18 Right hand side inverter TIG 150 DC Abb. 19 Rechte Seite inverter TIG 200 DC powersinus Fig. 19 Right hand side inverter TIG 200 DC powersinus Abb. 20 Rechte Seite inverter TIG 250 DC und inverter TIG 300 DC Fig. 20 Right hand side inverter TIG 250 DC and inverter TIG 300 DC 9/7

40 9 Ersatzteilliste / Spare parts list Pos. Bezeichnung: Type inverter TIG150DC inverter TIG200DC powersinus inverter TIG250DC inverter TIG300DC 1 PCB Sperrwandler PCB blocking converter 2 PCB Hauptregelungselektronik PCB main regulator electr.onic SPW3/ TRSQW3/200/1 TRDC2/250/6 TRDC2/300/ Durchflußwandler DC 5.0/220V Netzgleichrichter Mains rectifier 5 Magnetventil Solenoid valve 6 PCB Hochsetzsteller PCB power factor correction 7 HF Filter HF filter 8 PCB WIG-Steuerung PCB TIG control IC PAL IC PAL 9 Zündgerät Ignition unit 10 PCB Lüfteransteuerung PCB fan control 11 Sekundär Gleichrichterdiode und Freilaufdiode Sec. diode rectifier recov. diode 12 Lüfter Fan 13 PCBSchutzbeschaltung PCB protective wiring 14 Sekundär Dioden Kühler Secundary diode cooler 15 PCB (Liftarc) PCB (liftarc) 16 Shunt Shunt B2 35/ PFC1/1PCB HF INTIG03/ L8 D1INTIG HF-DC1/ Relais MDDM F02 MDDM F02 DSB1/1 DSB3/5 SDK 2x MDDM F02-01/3 SDK 2x MDDM F02-01/ Lift 1/DC A/60mV 250A/60mV /8

41 10 Zubehör 10.1 Torches / electrode holders Description Designation Article No. Electrode holder with 4 m cable 50 mm 2 EH Electrode holder with 4 m cable 70 mm 2 EH Workpiece lead with 4 m cable 50 mm 2 and clamp WK50QMM-4M/K "ASM" potentiometer torch connection OW ASM Potibrenner Workpiece lead with 4 m cable 70 mm 2 and clamp WK70QMM-4M/K TIG-Poti-torch, gas, central SRT17 1Poti GZ, 4m TIG-Poti- torch, gas, decentralised SRT17 1Poti GD, 4m TIG-Poti- torch, gas, central SRT26 1Poti GZ, 4m TIG-Poti- torch, gas, decentralised SRT26 1Poti GD, 4m TIG-Poti- torch, water, central SRT18 1Poti WZ, 4m TIG-Poti- torch, water, decentralised SRT18 1Poti WD, 4m TIG-Poti- torch, water, central SRT20 1Poti WZ, 4m TIG-Poti- torch, water, decentralised SRT20 1Poti WD, 4m For operation with a TIG poti torch the machine has to be equipped with the option connection poti torch possible! 10.2 Remote controls Description Designation Article No. Manual remote control spot / pulse with 5 m cable FRP Manual remote control current / spot / pulse with FRP m cable Manual remote control current with 5 m cable FR Manual remote control hotstart with 5 m cable FR Manual remote control current with digital amm. FRA and 0.3 m cable Foot-operated remote control current with 5 m cable FR Extension cable for remote controls with 3 m cable FRV Extension cable for remote controls with 5 m cable FRV Extension cable for remote controls with 10 m cable FRV Miscellaneous accessories Description Designation Article No. Adhesive film label "400V cable" /1

42 11 HF pulse generator HF-DC1/42 and ZGP1/ Before all work on the pulse generator, switch off the supply voltage and remove the mains plug! Repairs by electricians only Technical data Type HF pulse generator HF-DC 1/42 ZGP 1/ Nominal input voltage 42VAC 42VAC Permissible deviation +/- 10% +/- 10% Rated frequency 50/60Hz 50/60Hz Rated input power 5VA 12VA Rated output peak voltage 8kV 8kV 11.2 Application Pulse generators for installation in current sources or electrical cabinets serve for non-contact ignition of the arc for welding with direct current. Optimum ignition characteristics are only ensured with torch tube package lengths up to max. 8m Maintenance The internal pulse generator, designed to ignite and stabilise the arc, delivers high-voltage ignition pulses whose power is to be applied without losses to the electrode. However, any dirt, dust, moisture, oil etc. reduces the insulating properties of the required air and creep gaps. It must therefore be ensured that the equipment is looked after and kept clean by regular maintenance. This also applies particularly to the torches (often heavy contamination in the area of the grip). Contamination here often becomes noticeable when the HF leads to "electrification". In principle, the applied HF is safe (high frequency characteristics, so-called skin effect), but can lead to startled reactions. When the HF becomes noticeable, it takes routes which reduce the power at the gap between the electrode and the workpiece. It is therefore essential to ensure that the torches are clean and looked after! The pulse generator itself is maintenance-free Safety precautions Due to the very short ignition pulses (< 1 µsec), the pulse voltage is not dangerous. However, unexpected "electrification" can cause alarm. Therefore, wear suitable protective clothing for welding (in the Federal Republic of Germany, to UVV/VBG 15). Use only well-insulated welding torches and electrode holders. Perform work on welding torches and replace the electrode only when the current source is switched off. 11/1

43 12 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. The lower the Ambient temperature, the cooler the air passing through the heat exchanger, therefore the higher the cooling effect. The operating pressure of the coolant is monitored by a pressure switch, in the case of pressure loss then the operation of the torch button control signal will be unlimited. The built in coolant recirculation pump is fitted with a protective current overload. The supply voltage for this unit is fed internally from the welding power source. Application Range: The power cooler, is only suitable for use in conjunction with the following welding machine inverter TIG 200 DC powersinus 12.2 Technical Data: power Cooler Mains voltage 1x230V Mains frequency 50/60Hz Max. torch loading 200A bei 35% ED Maximum cooling capacity 1800 W Maximum coolant pressure 3,8 bar Working temperature range -10 C up to +40 C Protection classification IP 23 Insulation classification H Type of cooling Lüfter Coolant contents 5 Liter Coolant type Coolant KF23E - 10 Weight 39kg (incl. inverter TIG 200 DC powersinus without coolant) Dimensions (LxBxH) 640 x 280 x 305mm Dimensions (LxBxH) 640 x 280 x 620mm incl. inverter TIG 200 DC powersinus 12.3 Operating elements front and rear views of power Cooler module Fig 21: Operating elements front and rear view of power cooler module with inverter TIG 200 DC powersinus 12/1

44 12 Instruction Manual for Power Cooler Air Blast A10 B10 C10 D10 E10 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 before proceeding further Operating environment The working life of the cooling unit can be seriously affected, by various amounts, of Dirt, Dust, Acids, Corrosive gases, or metallic particles being present in the air of the working environment. Position the machine so that the Air flow into and out of the unit is completely unrestricted. Coolant The machine becomes from factory with a coolant-minimum filling KF23E-10 delivered. With the coolant KF23E-10 is guaranteed antifreezes to 10 C! Coolant stood examine and if necassary up to the upper shop-window of the tank (C10) coolants KF23E-10 (Article No.: if accessory see) refill. Using a mixture of other coolants, or using a coolant other than one prescribed above will void the manufacturers guarantee. The filter must be in the filler rack when filling the unit. Characteristic of the integrated water pump Putting: H [in m] P [in W] Q [l/min] Q [m 3 /h] conveyor high submitted pumping power conveyor quantity conveyor quantity The power cooler is now ready for use! 12/2

45 12 Instruction Manual for Power Cooler Air Blast 12.5 Spare parts list: Fig 23: left hand side power Kühlmodul Fig 24: right hand side power Kühlmodul Fig 22: Front view power Cooler with inverter TIG 200 DC powersinus Pos. Description: power Cooler 1 Side panel (left) Rubber feet Water connection (blue) Water connection (red) Housing cover Side panel (right) Fan Overload - 9 Recirculating Pump Druckschalter Heat exchanger Tank KF 23E /3