EWM PHB 50 20 A User manual

Operating instructions
EN
welding torch
PHB 50 20 A
PHB 50 50 A
099-002025-EW501
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29.11.2017
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General instructions
WARNING
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read and observe the operating instructions for all system components, especially the
safety instructions and warning notices!
•Observe the accident prevention regulations and any regional regulations!
•The operating instructions must be kept at the location where the machine is operated.
•Safety and warning labels on the machine indicate any possible risks.
Keep these labels clean and legible at all times.
•The machine has been constructed to state-of-the-art standards in line with any applicable
regulations and industrial standards. Only trained personnel may operate, service and
repair the machine.
•Technical changes due to further development in machine technology may lead to a
differing welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com.
Liability relating to the operation of this equipment is restricted solely to the function of the
equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of
liability shall be deemed accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and
methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a
result. For this reason, we do not accept any responsibility or liability for losses, damages or
costs arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG
Dr. Günter-Henle-Straße 8
56271 Mündersbach
Germany
The copyright to this document remains the property of the manufacturer.
Copying, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change; errors excepted.

Contents
Notes on the use of these operating instructions
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1 Contents
1Contents..................................................................................................................................................3
2For your safety .......................................................................................................................................4
2.1 Notes on the use of these operating instructions ..........................................................................4
2.2 Explanation of icons.......................................................................................................................5
2.3 Part of the complete documentation..............................................................................................6
3Intended use...........................................................................................................................................7
3.1 Applications....................................................................................................................................7
3.2 Documents which also apply .........................................................................................................7
3.2.1 Warranty.........................................................................................................................7
3.2.2 Declaration of Conformity...............................................................................................7
3.2.3 Service documents (spare parts) ...................................................................................7
4Machine description –quick overview ................................................................................................8
4.1 PHB 50...........................................................................................................................................8
4.2 Connection.....................................................................................................................................9
5Design and function.............................................................................................................................10
5.1 Welding torch cooling system......................................................................................................11
5.2 Commissioning ............................................................................................................................12
5.2.1 Preparations .................................................................................................................12
5.2.2 Start of welding.............................................................................................................12
5.2.3 Setting the electrode.....................................................................................................12
5.2.4 Selecting the nozzle .....................................................................................................12
5.2.5 Double arc ....................................................................................................................13
5.2.6 Grinding the electrode..................................................................................................13
5.3 Welding parameters.....................................................................................................................14
5.3.1 Main welding parameters .............................................................................................14
5.3.2 Plasma gas...................................................................................................................14
5.3.3 Shielding gas supply (shielding gas cylinder for welding machine) .............................14
5.3.4 Operating instructions...................................................................................................14
5.4 Electrode replacement.................................................................................................................15
6Maintenance, care and disposal.........................................................................................................17
6.1 General ........................................................................................................................................17
6.2 Cleaning.......................................................................................................................................17
6.2.1 Dirt filter ........................................................................................................................17
6.3 Maintenance work, intervals ........................................................................................................18
6.3.1 Daily maintenance tasks...............................................................................................18
6.3.2 Monthly maintenance tasks..........................................................................................18
6.3.3 Annual test (inspection and testing during operation)..................................................18
6.4 Disposing of equipment ...............................................................................................................19
7Rectifying faults ...................................................................................................................................20
7.1 Checklist for rectifying faults........................................................................................................20
7.2 Vent coolant circuit.......................................................................................................................22
8Technical data ......................................................................................................................................23
8.1 PHB 50.........................................................................................................................................23
9Replaceable parts ................................................................................................................................24
9.1 PHB 50.........................................................................................................................................24
10 Appendix A ...........................................................................................................................................25
10.1 Overview of EWM branches ........................................................................................................25

For your safety
Notes on the use of these operating instructions
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2 For your safety
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
•Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
•The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
•Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
•The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
•The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
•The risk is explained using a symbol on the edge of the page.
Special technical points which users must observe.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
•Insert the welding current lead socket into the relevant socket and lock.

For your safety
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Symbol
Description
Indicates technical aspects which the
user must observe.
Activate and release/tap/tip
Switch off machine
Release
Switch on machine
Press and keep pressed
Switch
Wrong
Turn
Correct
Numerical value –adjustable
Menu entry
Signal light lights up in green
Navigating the menu
Signal light flashes green
Exit menu
Signal light lights up in red
Time representation (e.g.: wait
4 s/activate)
Signal light flashes red
Interruption in the menu display (other
setting options possible)
Tool not required/do not use
Tool required/use

For your safety
Part of the complete documentation
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2.3 Part of the complete documentation
These operating instructions are part of the complete documentation and valid only in
combination with all other parts of these instructions! Read and observe the operating
instructions for all system components, especially the safety instructions!
The illustration shows a general example of a welding system.
Figure 2-1
Item
Documentation
A.1
Power source
A.2
Welding torch
A
Complete documentation

Intended use
Applications
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3 Intended use
WARNING
Hazards due to improper usage!
The machine has been constructed to the state of the art and any regulations and
standards applicable for use in industry and trade. It may only be used for the welding
procedures indicated at the rating plate. Hazards may arise for persons, animals and
material objects if the equipment is not used correctly. No liability is accepted for any
damages arising from improper usage!
•The equipment must only be used in line with its designated purpose and by trained or
expert personnel!
•Do not improperly modify or convert the equipment!
3.1 Applications
Welding torches for arc welding systems for plasma welding.
3.2 Documents which also apply
3.2.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.2.2 Declaration of Conformity
The labelled machine complies with the following EC directives in terms of its design and
construction:
•Low Voltage Directive (LVD)
•Electromagnetic Compatibility Directive (EMC)
•Restriction of Hazardous Substance (RoHS)
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc
Welding Equipment –Inspection and Testing during Operation," and/or prohibited modifications which
have not been explicitly authorised by the manufacturer, this declaration shall be voided. An original
document of the specific declaration of conformity is included with every product.
3.2.3 Service documents (spare parts)
WARNING
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
•Appoint only skilled persons for repair work (trained service personnel)!
Spare parts can be obtained from the relevant authorised dealer.

Machine description –quick overview
PHB 50
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4 Machine description – quick overview
4.1 PHB 50
Figure 4-1
Item
Symbol
Description 0
1
Tungsten electrode
2
Gas nozzle
3
Back cap
4
Grip plate

Machine description –quick overview
Connection
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4.2 Connection
Figure 4-2
Item
Symbol
Description 0
1
M12x1 coolant water nipple
Water flow
2
M12x1 coolant water nipple
Water return
3
G 1/4" connecting nipple
Shielding gas
4
G 1/4" connecting nipple
Plasma gas
5
Connector plug, welding current
Welding current connection for torch
6
Connector plug, pilot arc current
Pilot arc power connection for torch

Design and function
Connection
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5 Design and function
WARNING
Risk of injury from electrical voltage!
Contact with live parts, e.g. power connections, can be fatal!
•Observe the safety information on the first pages of the operating instructions!
•Commissioning must be carried out by persons who are specifically trained in handling
power sources!
•Connect connection or power cables while the machine is switched off!
CAUTION
Risk from electrical current!
If welding is carried out alternately using different methods and if a welding torch and
an electrode holder remain connected to the machine, the open-circuit/welding voltage
is applied simultaneously on all cables.
•The torch and the electrode holder should therefore always be placed on an insulated
surface before starting work and during breaks.
Read and observe the documentation to all system and accessory components!

Design and function
Welding torch cooling system
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5.1 Welding torch cooling system
Use of unsuitable coolants results in damage to the welding torch!
Unsuitable coolants can cause damage to the welding torch!
•Use only KF 23E coolants (observe temperature range of - 10 °C bis + 40°C).
Coolant mixtures!
Mixtures with other liquids or the use of unsuitable coolants result in material damage and
renders the manufacturer's warranty void!
•Only use the coolant described in this manual (overview of coolants).
•Do not mix different coolants.
•When changing the coolant, the entire volume of liquid must be changed.
Dispose of the coolant in accordance with local regulations and the material safety data sheets
(German waste code number: 70104).
May not be disposed of in household waste.
Prevent entry into sewers.
Absorb with liquid-binding material (sand, gravel, acid-binding agents, universal binding agents,
sawdust).
Figure 5-1
Part of the heat is transferred via the plasma nozzle and gas lens to the torch cooling system (1), another
part is blown (3) from the torch by the shielding gas (2).
The large contact area of the electrode offers several advantages:
•Optimum cooling
•Optimum flow transfer
•Long electrode service life

Design and function
Commissioning
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5.2 Commissioning
5.2.1 Preparations
Let the plasma gas flow through the torch for several minutes so as to purge it from any air humidity and
avoid ignition problems.
5.2.2 Start of welding
Before starting to weld, the arc has to briefly stabilise.
At this stage, the burning pilot arc is not centred.
Figure 5-2
5.2.3 Setting the electrode
When starting a new welding task, the electrode has to be re-set.
Turn the collet casing adjusting ring to optimally set the arc.
You can transfer the electrode position to the electrode gauge to keep using it for the same task.
5.2.4 Selecting the nozzle
To ensure an optimum service life of the nozzles, don’t operate the nozzle above the maximum current.
If necessary, switch to a nozzle of the next size.
The nozzle service life is also affected by the plasma gas quantity used.
The following applies: The lower the plasma gas quantity, the shorter the service life.
As a reference, take the nozzle diameter (same value or multiplied by factor 1.5) as distance between
plasma nozzle and workpiece.

Design and function
Welding parameters
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5.2.5 Double arc
When the current load is too high or the torch held at too steep an angle, a second arc will form between
workpiece and plasma nozzle.
When the current load is too high or the torch held at too steep an angle, the nozzle service life
will decrease significantly.
Figure 5-3
5.2.6 Grinding the electrode
The electrodes for plasma welding should be grinded mechanically. This will increase the electrode
service life and the welding result will become reproducible.
The grinding angle for cathode welding is 30° (setting angle 15°).
The anode electrode, whose tip is balled or semispherical during operation, is pre-grinded with a bevel of
about 1 mm and at a bevel angle of 45°. It will develop its final form for welding after brief loading in the
higher current range (approx. 35 A)
The regrinding lengths depend on the maximum current load.
The following applies: The lower the actual current load during operation, the more frequently you can
regrind an electrode.

Design and function
Welding parameters
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5.3 Welding parameters
5.3.1 Main welding parameters
•Welding current
•Plasma quantity
•Shielding gas
5.3.2 Plasma gas
The plasma gas used is generally Argon.
5.3.3 Shielding gas supply (shielding gas cylinder for welding machine)
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders can cause
serious injuries!
•Observe the instructions from the gas manufacturer and any relevant regulations
concerning the use of compressed air!
•Do not attach any element to the shielding gas cylinder valve!
•Prevent the shielding gas cylinder from heating up.
An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a
fundamental requirement for optimum welding results. In addition, a blocked shielding gas
supply may result in the welding torch being destroyed.
•Always re-fit the yellow protective cap when not using the shielding gas connection.
•All shielding gas connections must be gas tight.
For most welding tasks
Mixed argon/hydrogen gas: Ar + 4-6.5%H2
For titan and aluminium materials
Pure argon
Aluminium
Helium and mixed argon/helium gases
5.3.4 Operating instructions
The plasma nozzle has to be selected based on the welding current used.
To form a stable plasma jet, different plasma nozzle diameters are recommended for the individual
currents:
Wire diameter
Current
Plasma gas
Shielding gas
0.6 mm
up to 6 A
0.3 l/min.
3.0 l/min.
0.8 mm
up to 12 A
0.3 l/min.
3.0 l/min.
1.0 mm
up to 18 A
0.4 l/min.
4.0 l/min.
–1.2 mm
up to 26 A
0.4 l/min.
4.0 l/min.
1.4 mm
up to 32 A
0.5 l/min.
5.0 l/min.
1.6 mm
up to 40 A
0.5 l/min.
5.0 l/min.
1.8 mm
up to 50 A
0.6 l/min.
6.0 l/min.
These data are reference values for welding operation at 60 duty cycle. Depending on the plasma
gas quantity, overlapping is allowed.

Design and function
Electrode replacement
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5.4 Electrode replacement
Figure 5-4
Item
Symbol
Description 0
1
Back cap
2
Collet chuck
3
Collet casing
4
Compensating spring
5
Electrode guide insert
6
Tungsten electrode
7
Setting gauge
8
Torch body
9
Insert tube, ceramic
10
Plasma nozzle
11
Gas nozzle

Design and function
Electrode replacement
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Observe the following order:
•From the rear, screw the electrode guide insert into the torch body.
•Insert the compensating spring.
•Screw in the collet body as far as it goes.
•Insert the collet chuck with the tungsten electrode.
•From the front, screw the setting gauge into the plasma nozzle thread as far as it goes so as to place
the tungsten electrode into the correct position.
•Screw the back cap into the threaded intermediate piece.
•Unscrew the setting gauge.
•From the front, insert the ceramic insert tube.
•Firmly screw in the plasma nozzle.
•Screw on the gas nozzle.
You can optimise the plasma jet at a later stage using the collet body. This way, you can slightly
change the position of the tungsten electrode.

Maintenance, care and disposal
General
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6 Maintenance, care and disposal
6.1 General
DANGER
Risk of injury due to electrical voltage after switching off!
Working on an open machine can lead to fatal injuries!
Capacitors are loaded with electrical voltage during operation. Voltage remains present
for up to four minutes after the mains plug is removed.
1.Switch off machine.
2.Remove the mains plug.
3.Wait for at last 4 minutes until the capacitors have discharged!
WARNING
Incorrect maintenance, testing and repair!
Maintenance, testing and repair of the machine may only be carried out by skilled and
qualified personnel. A qualified person is one who, because of his or her training,
knowledge and experience, is able to recognise the dangers that can occur while testing
welding power sources as well as possible subsequent damage, and who is able to
implement the required safety procedures.
Observe the maintenance instructions.
•In the event that the provisions of one of the below-stated tests are not met, the machine
must not be operated again until it has been repaired and a new test has been carried out!
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the
right to claim under warranty is void. In all service matters, always consult the dealer who supplied the
machine. 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, please quote the
machine type, serial number and item number of the machine, as well as the type designation and item
number of the spare part.
Under the specified ambient conditions and normal working conditions this machine is essentially
maintenance-free and requires just a minimum of care.
Contamination of the machine may impair service life and duty cycle. The cleaning intervals depend on
the ambient conditions and the resulting contamination of the machine. The minimum interval is every six
months.
6.2 Cleaning
•Clean the outer surfaces with a moist cloth (no aggressive cleaning agents).
•Purge the machine venting channel and cooling fins (if present) with oil- and water-free compressed
air. Compressed air may overspeed and destroy the machine fans. Never direct the compressed air
directly at the machine fans. Mechanically block the fans, if required.
•Check the coolant for contaminants and replace, if necessary.
6.2.1 Dirt filter
The duty cycle of the welding machine decreases as an effect of the reduced cooling air volume.
Depending on the amount of dirt building up (at least every two months), the dirt filter has to be
uninstalled and cleaned regularly (e.g. by purging with compressed air).

Maintenance, care and disposal
Maintenance work, intervals
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6.3 Maintenance work, intervals
6.3.1 Daily maintenance tasks
Visual inspection
•Mains supply lead and its strain relief
•Gas cylinder securing elements
•Check hose package and power connections for exterior damage and replace or have repaired by
specialist staff as necessary!
•Gas tubes and their switching equipment (solenoid valve)
•Check that all connections and wearing parts are hand-tight and tighten if necessary.
•Check correct mounting of the wire spool.
•Wheels and their securing elements
•Transport elements (strap, lifting lugs, handle)
•Other, general condition
Functional test
•Operating, message, safety and adjustment devices (Functional test)
•Welding current cables (check that they are fitted correctly and secured)
•Gas tubes and their switching equipment (solenoid valve)
•Gas cylinder securing elements
•Check correct mounting of the wire spool.
•Check that all screw and plug connections and replaceable parts are secured correctly, tighten if
necessary.
•Remove any spatter.
•Clean the wire feed rollers on a regular basis (depending on the degree of soiling).
6.3.2 Monthly maintenance tasks
Visual inspection
•Casing damage (front, rear and side walls)
•Wheels and their securing elements
•Transport elements (strap, lifting lugs, handle)
•Check coolant tubes and their connections for impurities
Functional test
•Selector switches, command devices, emergency stop devices, voltage reducing devices, message
and control lamps
•Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.
•Check coolant tubes and their connections for impurities
•Check and clean the welding torch. Deposits in the torch can cause short circuits and have a negative
impact on the welding result, ultimately causing damage to the torch.
6.3.3 Annual test (inspection and testing during operation)
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition
to the regulations on testing given here, the relevant local laws and regulations must also be observed.
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!

Maintenance, care and disposal
Disposing of equipment
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6.4 Disposing of equipment
Proper disposal!
The machine contains valuable raw materials, which should be recycled, and electronic
components, which must be disposed of.
•Do not dispose of in household waste!
•Observe the local regulations regarding disposal!
•According to European provisions (Directive 2012/19/EU on Waste of Electrical and Electronic
Equipment), used electric and electronic equipment may no longer be placed in unsorted municipal
waste. It must be collected separately. The symbol depicting a waste container on wheels indicates
that the equipment must be collected separately.
This machine has to be disposed of, or recycled, in accordance with the waste separation systems in
use.
•According to German law (law governing the distribution, taking back and environmentally correct
disposal of electric and electronic equipment (ElektroG)), used machines are to be placed in a
collection system separate from unsorted municipal waste. The public waste management utilities
(communities) have created collection points at which used equipment from private households can be
disposed of free of charge.
•Information about returning used equipment or about collections can be obtained from the respective
municipal administration office.
•In addition to this, returns are also possible throughout Europe via EWM sales partners.

Rectifying faults
Checklist for rectifying faults
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7 Rectifying faults
All products are subject to rigorous production checks and final checks. If, despite this, something fails to
work at any time, please check the product using the following flowchart. If none of the fault rectification
procedures described leads to the correct functioning of the product, please inform your authorised
dealer.
7.1 Checklist for rectifying faults
The correct machine equipment for the material and process gas in use is a fundamental
requirement for perfect operation!
Legend
Symbol
Description

Fault/Cause

Remedy
Welding torch overheated
Insufficient coolant flow
Check coolant level and refill if necessary
Eliminate kinks in conduit system (hose packages)
Vent coolant circuit
Loose welding current connections
Tighten power connections on the torch and/or on the workpiece
Tighten contact tip correctly
Overload
Check and correct welding current setting
Use a more powerful welding torch