EWM inverter STICK 250 H-2 User manual

EWM HIGHTEC WELDING GmbH
Dr.-Günter - Henle - Straße 8; D-56271 Mündersbach
Phone: [phone]; Fax: [phone]
Internet: www.ewm.de ; E-mail: [email protected]
Operating instructions
GB
Inverter STICK Welding Machines
from 250A to 350A, portable
inverter STICK 250 H-2
inverter STICK 350 CEL
inverter STICK 350 CEL KLR
inverter STICK 350 CEL PWS
These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machine 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 Directive (73/23/EEC)
•EC EMC Directive (89/336/EEC)
Geräte können entsprechend IEC 60974, EN 60974, VDE 0544 in Umgebung mit erhöhter
elektrischer Gefährdung eingesetzt werden.
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ã2002 Subject to alteration. Item No.: 099-002029-EWM01 Version: 07.08.02

Originaldokument
liegt jedem Gerät bei!
Original document
is enclosed with each machine!
Document original
est joint à toute machine!
EG - Konformitätserklärung
EU - conformity declaration
Déclaration de Conformité de U.E.
Name des Herstellers:
Name of manufacturer:
Nom du fabricant:
EWM HIGHTEC WELDING GmbH
(nachfolgend EWM genannt)
(In the following called EWM)
(nommé par la suite EWM)
Anschrift des Herstellers:
Address of manufacturer:
Adresse du fabricant:
Dr.- Günter - Henle - Straße 8
D - 56271 Mündersbach –Germany
[e-mail]
Hiermit erklären wir, daßdas
nachstehend bezeichnete Gerät in
seiner Konzeption und Bauart sowie in
der von uns in Verkehr gebrachten
Ausführung den grundlegenden
Sicherheits-anforderungen 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.
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
modèle, 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 inadéquates et / ou de
modifications prohibeés, qui n´ont pas été
autorisés expressément par EWM, cette
déclaration devient caduque.
Gerätebezeichnung:
Description of the machine:
Déscription de la machine:
Gerätetyp:
Type of machine:
Type de machine:
Artikelnummer EWM:
Article number:
Numéro d´article
Seriennummer:
Serial number:
Numéro de série:
Optionen:
Options:
Options:
keine
none
aucune
Zutreffende EG - Richtlinien:
Applicable EU - guidelines:
Directives de la U.E. applicables:
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
Angewandte harmonisierte Normen:
Used co-ordinated norms:
Normes harmonisées appliquées:
EN 60974 / IEC 60974 / VDE 0544
EN 50199 / VDE 0544 Teil 206
Hersteller - Unterschrift:
Signature of manufacturer:
Signature du fabricant:
Michael Szczesny , Geschäftsführer
managing director
gérant 05.2000

Table of contents Page
Contents/1
Safety instructions..............................................................................................................................S/1
For your safety............................................................................................................................S/1
Transport and Installation...........................................................................................................S/3
Ambient conditions.....................................................................................................................S/3
Notes on the use of these operating instructions.......................................................................S/3
1 Technical data........................................................................................................................... 1/1
1.1 Area of application............................................................................................................ 1/1
2 Description of the machine .....................................................................................................2/1
3 Function specification for logic control................................................................................. 3/1
3.1 Logic control..................................................................................................................... 3/1
3.2 Function sequence for MMA welding............................................................................... 3/2
3.3 Remote control................................................................................................................. 3/3
4 Quick start – the fastest way to weld ..................................................................................... 4/1
5 Commissioning......................................................................................................................... 5/1
5.1 Area of application............................................................................................................ 5/1
5.1.1 Proper usage.......................................................................................................... 5/1
5.2 Setting up the welding machine....................................................................................... 5/1
5.3 Mains connection .............................................................................................................5/1
5.4 Welding machine cooling system.....................................................................................5/1
5.5 Workpiece lead................................................................................................................. 5/1
5.6 Electrode holder............................................................................................................... 5/1
6 Maintenance and care.............................................................................................................. 6/1
7 Operating problems, causes and remedies........................................................................... 7/1
7.1 Customer checklist...........................................................................................................7/1
8 Spare parts list.......................................................................................................................... 8/1
8.1 Front view......................................................................................................................... 8/1
8.2 Rear view ......................................................................................................................... 8/2
8.3 inverter STICK 250H-2........................................................................................................... 8/3
8.3.1 Right-hand side...................................................................................................... 8/3
8.3.2 From above............................................................................................................ 8/3
8.3.3 Left-hand side ........................................................................................................ 8/4
8.4 inverter STICK 350 / 350CEL / 350CEL PWS .......................................................................8/5
8.4.1 Right-hand side...................................................................................................... 8/5
8.4.2 From above............................................................................................................ 8/6
8.4.3 Left-hand side ........................................................................................................ 8/6
9 Accessories, options ............................................................................................................... 9/1
9.1 Remote control................................................................................................................. 9/1
9.1.1 STICK 250 H-2 / 350 CEL / 350 CEL / 350 CEL KLR / 350 CEL PWS................. 9/1
9.1.2 STICK 350 CEL PWS............................................................................................ 9/1
9.2 General accessories......................................................................................................... 9/1
9.2.1 STICK 250 H-2....................................................................................................... 9/1
9.2.2 STICK 350 CEL / 350 CEL / 350 CEL KLR / 350 CEL PWS................................. 9/1
10 Circuit diagrams ..................................................................................................................... 10/1
10.1 STICK 250 H-2............................................................................................................... 10/1
10.2 STICK 350 CEL.............................................................................................................. 10/2
10.3 STICK 350 CEL KLR...................................................................................................... 10/3
10.4 STICK 350 CEL PWS..................................................................................................... 10/4

Safety instructions
S/1
For Your Safety:
Ignoring the following safety precautions can be fatal.
Observe accident prevention regulations.
Designed use
This machine is manufactured according to the current state of the art and current regulations and
standards. It is to be operated only for the designed use (see Chap. Commissioning/Area of
application).
Use not as designed
This machine may be a hazard to persons, animals and property, however, if it is
·not used as designed
·used by unskilled persons who have not been trained,
·modified or converted improperly
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.
Any person involved in operation, maintenance and repair of this machine must read and follow
these operating instructions, especially the safety precautions. Where appropriate, this must be
confirmed by signature.
Furthermore, the
·relevant accident prevention regulations,
·generally recognized safety regulations,
·regionally specific provisions etc. are to be adhered to.
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.
·The machine must not be used to defrost pipes.
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.

Safety instructions
S/2
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.
·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.