New Products 2014/2015. Blue Evolution. /// simply more. /// Perfection is the Principle. BlueEvolution the major sustainability initiative from ewm.

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1 New Products 2014/2015 Blue Evolution BlueEvolution the major sustainability initiative from ewm. Years Years transformer 3 5 and rectifier ewm-warranty warr 24 hours a a a a a a ant 7 days / Perfection is the Principle / simply more EWM AG /

2 Welding machines TIG-DC TETRIX 200 puls, TETRIX 300 puls TIG MMA max. 100 m Perfect TIG and MMA welding Experience undreamed-of TIG welding properties due to a new innovative power unit, the novelties Tetrix 200 puls and Tetrix 300 puls enable MMA pulse welding in addition to longer duty cycles, much improved ignition and welding properties and a higher open circuit voltage. They convince with their low weight, compact design and the option to connect to up to 100 m of mains cable both a the construction site and in the workshop. Your benefits Mains cable up to 100 m 100 % generator compatibility High mains voltage tolerances Tetrix 200 puls portable, gas-cooled Mains voltage: 1 x 230 V (-40 % %) Mains fuses: 1 x 16 A Open circuit voltage: 63 V Setting range: 5 A A Duty cycle 40 C: 200 A / 25 % 150 A / 60 % 120 A / 100 % cos φ: 0,99 Efficiency: 86% Tetrix 300 puls modular: portable, gas-cooled Mains voltage: 3 x 400 V (-25 % %) Mains fuses: 3 x 16 A Open circuit voltage: 63 V Setting range: 5 A A Duty cycle 40 C: 300 A / 25 % 260 A / 60 % 210 A / 100 % cos φ: 0,99 Efficiency: 88 % Tetrix 300 puls / cool40 U31 / Trolly modular: mobile, water-cooled Cooling capacity 1 l/min: 900 W max. flow rate: 5l/min max. output pressure: 3,5 bar tank capacity: 4 l 2 /

3 Vertical-up weld PF Vertical-down wld PG Your benefits MMA pulsing Especially suitable for root welding Reliable vertical down welding Perfect electrode vertical-up welding Fine-flaked weld surface with a TIG look for final passes Less finishing work thanks to less spatter Ideal for difficult electrodes Outstanding gap bridging with no sagging of the root side Less distortion thanks to controlled heat input Smart Very simple to operate just switch on and start welding One-knob operation and clear, self-explanatory operating panel TIG and MMA Spotmatic saves 50% of tacking time TIG automated pulsing MMA pulsing activarc precise, focussed arc with reduced heat transfer and deep fusion penetration for optimum root fusion Connection capability: remote control, up/down torch Comfort Proven convenience all welding parameters can be adjusted Reproducible setting of all welding parameters by means of digital display TIG and MMA activarc precise, focussed arc with reduced heat transfer and deep fusion penetration for optimum root fusion Pulsed TIG welding in Hz and khz ranges MMA pulsing Spotmatic saves 50% of tacking time Connection capability: remote control, up/ down and Retox torches Also ideal for mechanised and automated applications EWM AG / 3

4 Automation solutions frontdrive the safe alternative to push-pull MIG/MAG automation The new robot welding torch for your automated application As there is no push, you have no downtimes and no synchronisation problems compared to conventional push-pull welding torch systems. The ewm frontdrive can be used with all conventional robotic systems and can thus be easily integrated into your production process. Your benefits Suitable for all MIG/MAG processes: MIG/MAG, MIG brazing, pulse, forcearc forcearc puls, coldarc coldarc puls, root Arc root Arc puls Excellently suitable for soft wires, thin sheet and steel processing Trouble-free and reliable working due to 4 driven rollers in the wire feeder Assembled system 4 /

5 Your benefits Benefits over push-pull Drive near the welding process Maximum TCP security Wire is fed or pulled from one place No synchronisation problems Less wear parts required Prepared for the future Excellently suitable for soft wires Excellently suitable for thin sheet processing and steel Increased productivity Components 4 drive rolls Colour-marked wire feed rolls Transparent polycarbonate hood Bayonet catch for hose package and torch neck Wire inching forward Wire inching reverse User-friendly handling 3 push-buttons: Wire inching forward and reverse and gas test Toolless roll exchange Roll pressure adjustable in five locking stages without tool Bayonet catch for hose package and torch neck Reproducible contact pressure Gas test EWM AG / 5

6 Automation solutions System example frontdrive welding torch system Completely equipped frontdrive system 2 frontdrive media box Tool-free connection of all cables Gas valve Optional gas monitoring 3 5 Industrial bus interface, BUSINTX 11 Industrial bus interface for integration into production/robotic applications Operating panel Operating panel for setting welding parameters for RC welding power sources without front control 4 alphaq 352 MM RC power source Multiprocess MIG/MAG pulse welding machine, MULTIMATRIX technology, without front control ewm frontdrive performance data Processes: MIG/MAG, MIG brazing, pulse, forcearc forcearc puls, coldarc coldarc puls, rootarc rootarc puls Welding consumables: Un- and low-alloy steels, high-alloy steels, low-alloy steels and copper alloys, nickel-base alloys, fluxed cored wires Wire diameter: mm Maximum output: 420 A at 60% duty cycle/40 C, gas cooled 6 /

7 Welding torch system layout Torch neck including consumables Quick-change system for torch neck and hose package Bayonet catch Drive Reliable wire feeding due to 4-roll drive Drive near the welding process Roller pressure adjustable in five locking stages without tool Direct view of the wire feed rolls Colour-marked rolls Exchangeable centre guide Hose package with powerconnector connection Especially reliable current transfer due to powerconnector Bayonet catch frontdrive media box Tool-free connection of all cables Gas valve Optional gas monitoring Collision sensor Robust structure High precision EWM AG / 7

8 Welding torches Special welding torches tailored to your application MIG/MAG TIG Plasma We build the welding torch to match your application In addition to our in-house series production of MIG/MAG welding torches, we build the welding torch for your application. In this way, we guarantee you the optimal component for your welding task for manual and automated welding. Your benefits Special torches Welding torches tailored to your application Own consumables guarantee long service life and best integration into the welding system Welding inside pipes with extra long torch neck and small bend radius 8 /

9 Your benefits Task: Welding inside steel structures ewm solution: Torch neck based on MT551W with a length of 1,500 mm Customer benefit Welding location well accessible Improved visibility of the seam Reduced costs due to use of standard MT replacement parts Task: Reduced downtimes during automated welding of steel structures ewm solution: Welding torch with water cooled gas nozzle and exchangeable gas nozzle tip Customer benefit The targeted cooling of the gas nozzle enables a duty cycle of 650 A/100% High cost savings due to separate exchange of the gas nozzle tip Other consumables are standard MT consumables Task: Space-saving welding torch for use at longitudinal carriages and orbital welding installations ewm solution: Automated welding torch based on AMT551W with a total length of just 61 mm Customer benefit More compact design of the longitudinal carriages Orbital welding installations require less space to go round the pipe. Reduced costs due to use of standard MT consumables EWM AG / 9

10 forcetig Completely new possibilities of TIG welding forcetig standard forcetig cold wire forcetig hot wire forcetig / patented * TIG joining process with an especially focused arc for greater penetration and faster welding speeds now also available in conjunction with tigspeed drive 4 rob EWM s new, patented* forcetig welding process takes TIG welding to places that could not previously have been imagined. This joining process enables a much higher energy density in the weld pool by way of an extremely concentrated welding arc and makes possible the fastest welding speeds. Power sources capable of delivering up to 500 A and1000 A are available for welding greater panel thicknesses Compared to conventional methods such as automated TIG welding or plasma keyhole welding, the ewm forcetig offers you a large number of advantages and improvements. Your benefits Higher welding speed Increased efficiency, less non-productive time Less energy per unit length due to the highly focussed TIG arc with high energy density Three possible operating modes forcetig forcetig cold wire forcetig hot wire * EP B1 10 /

11 Your benefits Comparison of standard TIG arc with forcetig Advantages over standard TIG Much better focused arc Deeper penetration 100% reproducible TCP, perfect for automated applications Electrode easy to change without gauges thanks to defined, calibrated geometry Very high current-carrying capacity, high current density Stable welding torch design for increased crash safety Standard TIG arc forcetig Comparison of plasma keyhole with forcetig Advantages over plasma keyhole Substantially higher welding speed at greater material thickness Long duty cycles of the welding torch (up to 800 A/100%) Easier to adjust same as with TIG welding Short training times due to very simple operation Very low maintenance costs due to reduction to a few, robust consumables Plasma keyhole forcetig FT 500: 500 A / 100 % FT 1000: 800 A / 100 % forcetig welding torch High torch power : FT 1000: 800 A at 100 % DC FT 500: 500 A at 100 % DC Electrode easy to change without gauges Stable welding torch design for increased crash safety Closed, highly effective cooling circuit Optionally with or without cold or hot wire feed FT 500 ideal in confined spaces thanks to its small size FT 1000 ideal for great wall thicknesses thanks to high performance EWM AG / 11

12 TIG hot and cold wire welding Dynamic wire feed system tigspeed drive 45 / tigspeed drive 4 Rob TIG welding TIG cold wire welding TIG hot wire welding tigspeed increases deposition rates, welding speeds and quality The continuous wire feeding is superimposed by a forward/backward motion of the wire. The welding process is particularly stable and offers a high deposition rate at the same time. The tigspeed systems are available as cold wire and hot wire versions for manual and automated operation. Up to 100% faster in comparison to manual TIG welding Less fatigue thanks to easier handling and more comfortable working positions Perfect weld, no spatters Your benefits tigspeed: forward/backward motion of the wire cold / hot wire tigspeed: forward/backward motion of the wire Up to 60% higher deposition rates* Better seam quality* thanks to significantly reduced dilution when surfacing Less fatigue * thanks to easier handling and more comfortable working positions Ideal for positional welding Perfectly controllable weld pool through superimposed forward/ backward motion of the wire Optimum seam appearance with shapeable ripples thanks to infinitely adjustable frequency of the forward/ backward motion of the wire Reliable welding of root passes with high welding speed 12 / *compared to manual TIG welding

13 Your benefits Manual application tigspeed drive 45 For connecting to standard TIG power sources (prepared for cold / hot wire) Set and view all parameters at tigspeed drive 45 Set parameters via remote control Remote control RTG U/D cold / hot wire Adjustable heat input in the wire from 40 A to 180 A TIG 200G CW HFL: 200 A / 35 % (DC) 140 A / 35 % (AC) TIG 450W CW/HW HFL: 400 A / 100 % (DC) 280 A / 100 % (AC) comfytig 18-1 CW/HW: 290 A / 100 % (DC) 190 A / 100 % (AC) Choice of 3 torches TIG 200G CW HFL: Gas cooled TIG welding torch, cold wire, up/down, 270 rotatable and replaceable wire feed TIG 450W CW/HW HFL: Water cooled TIG welding torch, cold/ hot wire, up/down, 270 rotatable and replaceable wire feed comfytig 18-1 CW/HW: Water-cooled TIG cold / hot wire torch in MIG/MAG torch casing Mechanised and automated applications tigspeed drive 4 Rob Setting and display of all parameters via BUSINTX 11 cold / hot wire Adjustable heat input in the wire from 40 A to 180 A For connection to tigspeed 353 Synergic RC cold wire and tigspeed 352 Synergic RC hot wire power sources Optionally available as tigspeed plasma power source 352 TIG-MT 200G 200 A / 60 % (DC) 140 A / 60 % (AC) TIG-MT 300 W 300 A / 100 % (DC) 210 A / 100 % (AC) TIG-MT 500 W 500 A / 100 % (DC) 350 A / 100 % (AC) EWM automated welding torches Automated TIG welding torch with cold / hot wire support 4 axes support Available for Tetrix drive, tigspeed and tigspeed drive 4 Rob available TIG-MT 200G, TIG-MT 300W, TIG-MT 500W EWM AG / 13

14 TIG torches New TIG welding products TIG welding comfytig 18-1 CW/ HW TIG 450W CW/HW TIG-SR 300 GD HD TIG welding made easy Our new TIG welding torch products convince in particular with improved handling of cold and hot wire welding, great robustness and long duty cycles. In addition to a world first in the field of TIG welding, our comfytig CW/HW, we offer you a large variety of variants of cold and hot wire torches. There are new things to discover also in the field of manual welding: For instance, you can now without a problem weld with up to 300 A with gas cooling with our TIG-SR 300 GD HD Your benefits TIG 200G CW TIG 450W CW/HW TIG welding torch, cold / hot wire, rotating support Ergonomic GRIP handle for a secure grip Three fixed or flexible wire feed angles Flexible use due to different gas nozzle forms such as Jumbo and torch neck gas nozzle comfytig 18-1 CW/HW Cold / hot wire torch in MIG/ MAG torch casing Three fixed or flexible wire feed angles Easy changeover from MIG/ MAG to TIG welding Flexible use due to different gas nozzle forms such as Jumbo and torch neck gas nozzle TIG-SR 300 GD HD Gas cooled TIG welding torch with high power: 300 A/ 35% TIG-SR 300F GD HD: Optimal ergonomics in all welding positions Flexible use due to different gas nozzle forms such as Jumbo and torch neck gas nozzle Compatible with SR consumables EWM TIG series: Components streamlined to three consumables Easier adjustment of tungsten needle Simpler, quicker change of consumables No copies, so optimum quality assured EWM TIG-SR series: Based on the SR standard available worldwide High power, gas cooled up to 300 A 14 /

15 TIG-SR 300 GD HD: 300 A / 35 % (DC) 250 A / 35 % (AC) TIG-SR 300F GD HD: 300 A / 35 % (DC) 250 A / 35 % (AC) Your benefits TIG torch with very high power Gas cooled TIG torch Heavy Duty: 300 A Compatible with SR consumables TIG-SR 300F GD HD: Optimal ergonomics in all welding positions Improved accessibility TIG 450W CW/HW 400 A / 100 % (DC) 280 A / 100 % (AC) TIG 200G CW 200 A / 35 % (DC) 140 A / 35 % (AC) View X X 30, 39, 42 TIG welding torch with a separate cold / hot wire feed Optionally gas (TIG 200 CW) or water-cooled (TIG 450 CW/HW) Up/Down: Setting of welding current and programs 270 rotatable and replaceable wire feed Three fixed wire feed angles: 30, 39, and 41 Flexible wire feed angle of Various gas nozzle forms Highly flexible hose package with 1 m leather protector Ergonomic GRIP handle for a secure grip Support flex wire feed angle comfytig 18-1 CW/HW 290 A / 100 % (DC) 190 A / 100 % (AC) 30, 39, 42 Cold / hot wire torch in MIG/MAG torch casing TIG welding torch with a separate cold / hot wire feed Three fixed wire feed angles: 30, 39, and 41 Flexible wire feed angle of Improved handling thanks to MIG/MAG torch grip Almost no adjustment needed when changing from MIG/MAG to cold or hot wire welding Various gas nozzle forms flex wire feed angle EWM AG / 15

16 Degaussing Degaussing prior to welding Degaussing Degauss 600 Magnetism is not desired where steel is welded. Undesired residual magnetism in steel parts results in an unstable and deflected arc. The effect may be so great that welding is impossible. When using the Degauss 600, you can degauss your materials and workpieces. Following the easy installation of the components at the workpiece, the continuous degaussing process will automatically be completed within the shortest possible time. The effect of the degaussing will show immediately in the subsequent welding process. Your welding results speak for themselves: The arc is stable and no longer deflected, there are no unnecessary ignition spots, sidewalls are fused without lack of fusion, perfect results without rework or scrap are achieved. Your benefits Degaussing of magnetic materials and workpieces Single button operation automatic degaussing Stable welding process without magnetic deflection perfect welding result without finishing work 16 /

17 Your benefits Degaussing of pipes and metal sheets User s advantages No deflection of the arc by residual magnetism in the workpiece Avoidance of lack of fusion due to insufficient sidewall fusion Minimisation of finishing work Cost-efficient and high-quality results Degaussing of pipes and metal sheets Very straightforward handling The set includes all components required for degaussing Quick connection at the pipe by means of three load cables Single button operation Automatic degaussing process Use at -25 C to +40 C with mains voltage tolerances of +/-20% Portable and robust Degauss 600 Compact degaussing power source suitable for use at the construction site Single button operation Automatic degaussing process EWM AG / 17

18 MMA / Degaussing Degaussing and welding with only one machine Degaussing MMA MAG CC-CV WIG (Liftarc) Especially durable Production-standard control panel protective cover Degaussing Automatic degaussing function to eliminate residual magnetism in pipes and sheets Polarity-reversing device Pico 350 cel puls pws dgs Resistant against cold, heat, rain or dirt, enormously rugged for the toughest usage and, thanks to low weight, ideal for changing deployment locations! 100% safe for vertical-down welding of CEL electrodes MAG welding with Pico drive 4L wire feed unit Degaussing of pipes and metal sheets Highly practical Rugged carrying handle with shoulder strap Production-standard mains cable bracket IP 34s protection All-round protection against splash water Integrated as standard equipment (PWS version) Best protection Protection against the ingress of foreign objects Insertable protective dust filter (optional) For tough jobs Secure penetration depth when placed in accumulated water Especially solidly-designed base Pico 350 cel puls pws dgs Mains voltage: 3 x 400 V (-25 % %) Mains fuses: 3 x 16 A Open circuit voltage: 95 V Setting range: 10 A A Duty cycle 40 C: 350 A / 35 % 280 A / 60 % 230 A / 100 % cos φ: 0,99 Efficiency: 88% + D 200 D 300 oder D 200 Pico 350 cel puls pws dgs with E 1.03 control unit (MMA Pro PWS) Selectable polarity Pico drive 4L or Pico drive 200 C Versatile usage thanks to MAG CC-CV for MAG welding and self-shielding for flux cored wire 18 /

19 Your benefits Built for the most extreme demands Inspected protection against splash water (IP 34s) Ruggedly-designed base enables placement in dirty and wet environments No ingress of accumulated water Durability because of replaceable filters 3-year guarantee, without any performance restrictions, also for 3-shift, 24-hour/7-day operations 5-year guarantee for transformer and rectifier Maximum functionality easiest operation Polarity can be reversed by pressing a button (PRS) Energy efficient due to standby mode Automatic degaussing process Easiest operation, also for novices, thanks to selfexplanatory, clearly-arranged user interface Vertical-up weld Vertical-down weld Very easy vertical-up and vertical-down welds 100% reliable vertical down welding Perfect electrode vertical-up welding through PF pulse function Pulsing (MMA pulsing) Automated pulsing max. 200 m For all climatic zones Temperature range of operating machines: -25 C to +40 C Temperature range for transport and storage: -30 C to +70 C100 % High mains voltage tolerances (-25% to +20%) 100% generator compatibility EWM AG / 19

20 Options Work made easy with our new options ON HS XX1 Securely transports long intermediate hose packages of up to 30 m With our new hose package holder long hose packages can be securely stored on the machine. For holding hose packages of up to 30 m Can be used with every mobile, non-modular ewm machine (XX1 casing) ON HS XX1 ON TC 55 Tools and wear parts always to hand With our new ON TC 55 tool box you do not need to search for tools any longer Tool box can be mounted to Trolley 55 All tools and wear parts to hand For use with gas-cooled, modular machines Easy mounting to trolley ON TC /

21 Notes EWM AG / 21

22 Notes 22 /

23 Headquarters EWM AG Dr. Günter-Henle-Straße Mündersbach Germany Tel: Fax: info@ewm-group.com Technology centre EWM AG Forststraße Mündersbach Germany Tel: Fax: info@ewm-group.com Production, Sales and Service EWM AG Dr. Günter-Henle-Straße Mündersbach Germany Tel: Fax: info@ewm-group.com TEAMWELDER s.r.o. Tř. 9. května 718 / Jiříkov Czech Republic Tel.: Fax: info@teamwelder.eu EWM HIGH TECHNOLOGY (Kunshan) Ltd. 10 Yuanshan Road, Kunshan New & Hi-tech Industry Development Zone Kunshan City Jiangsu Post code People s Republic of China Tel: Fax: info@ewm.cn info@ewm-group.cn Sales and Service Germany EWM AG Sales and Logistics Centre Sälzerstraße 20a Ransbach-Baumbach Tel: Fax: info@ewm-ransbach-baumbach.de EWM AG Sales and Technology Centre Grünauer Fenn Rathenow Tel: Fax: info@ewm-rathenow.de EWM AG Rudolf-Winkel-Straße Göttingen Tel: Fax: info@ewm-goettingen.de EWM AG Sachsstraße Pulheim Tel: Fax: info@ewm-pulheim.de EWM AG August-Horch-Straße 13a Koblenz Tel: Fax: info@ewm-koblenz.de EWM AG Eiserfelder Straße Siegen Tel: Fax: -9 info@ewm-siegen.de EWM HIGHTEC WELDING GmbH Sales and Technology Centre Draisstraße 2a Weinheim Tel: Fax: info@ewm-weinheim.de EWM Schweißtechnik Handels GmbH Karlsdorfer Straße Tettnang Tel: Fax: info@ewm-tettnang.de EWM Schweißtechnik Handels GmbH Pfaffensteig Blaubeuren Tel: Fax: info@ewm-blaubeuren.de EWM Schweißtechnik Handels GmbH Heinkelstraße Neu-Ulm Tel: Fax: info@ewm-neu-ulm.de Sales and Service International EWM HIGHTEC WELDING GmbH Wiesenstraße 27b 4812 Pinsdorf Austria Tel: Fax: info@ewm-austria.at EWM HIGH TECHNOLOGY (Kunshan) Ltd. 10 Yuanshan Road, Kunshan New & Hi-tech Industry Development Zone Kunshan City Jiangsu Post code People s Republic of China Tel: Fax: info@ewm.cn info@ewm-group.cn EWM HIGHTEC WELDING UK Ltd. Unit 2B Coopies Way Coopies Lane Industrial Estate Morpeth Northumberland NE61 6JN Great Britain Tel: Fax: info@ewm-morpeth.co.uk EWM HIGHTEC WELDING Sales s.r.o. / Prodejní a poradenské centrum Tyršova Benešov u Prahy Czech Republic Tel: Fax: info@ewm-benesov.cz Plants Branches More than 400 EWM sales partners worldwide

24 Rathenow ewm worldwide Göttingen Czech Republic Benešov u Prahy Pulheim People's Republic of china Kunshan Siegen Mündersbach Koblenz Austria Pinsdorf Ransbach-Baumbach Great Britain Morpeth Weinheim Blaubeuren Neu-Ulm Tettnang Plants Branches Sales partners More than 400 ewm sales partners worldwide we re never far away. Headquaters Technology Centre Sales and Logistics Centre EWM AG Dr. Günter-Henle-Straße 8 D Mündersbach Tel: Fax: info@ewm-group.com EWM AG Forststraße 7-13 D Mündersbach Tel: Fax: info@ewm-group.com EWM AG Sälzerstraße 20a D Ransbach-Baumbach Tel: Fax: info@ewm-sales.com Sales / Consultancy / Service The content of this document has been prepared and reviewed with all reasonable care. The information provided is subject to change, errors excepted. WM / / EWM AG Visit us!

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