EWM inverter TIG 150 DC 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
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 60974-1), the machines can be used in environments with
an increased electrical hazard.
2000 We reserve the right to make amendments. Art. No.: 099-000016-EWM01 Revised: 28.08.2000

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 Conformidité 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
[email protected]
Hiermit erklären wir, daß das nachstehend
bezeichnete Gerät in seiner Konzeption und
Bauart sowie in der von uns in Verkehr ge-
brachten 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.
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 devientcaduque.
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 Content Page
Inhalt/1
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........................................................................................................................ 3/10
3.7 Interface for mechanised welding (remote control connection socket)..................................... 3/12
4Quick start – the shortest way to welding........................................................................................ 4/1

Table of Content Page
Inhalt/2
5 Commissioning................................................................................................................................... 5/1
5.1 Setting up the welding machine.................................................................................................. 5/1
5.2 Mains connection........................................................................................................................ 5/1
5.2.1 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...................................................... 5/2
5.6.1 TIG welding torch connection........................................................................................... 5/3
5.6.2 TIG potentiometer welding torch connection.................................................................... 5/3
5.7 Shielding gas supply................................................................................................................... 5/3
5.7.1 Establishing the gas connections..................................................................................... 5/3
5.7.2 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 ZGP1/8.0-4............................................................................. 11/1
12 Instruction Manual for Power Cooler Air Blast
Cooler Unit for a
inverter
TIG 200 DC
powerSinus
........................................................................................... 12/1
12.1 Description of Unit.......................................................................................................... 12/1
12.2 Technical Data................................................................................................................ 12/1
12.3 Operating Elements Front and Rear Views of Power Cooler Module ............................ 12/1
12.4 Commissioning............................................................................................................... 12/2
12.5 Spare Parts List.............................................................................................................. 12/3
13. Circuit diagrams................................................................................................................................ 13/1

Safety instructions
Safety /1
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 instructions
Safety /2
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 instructions
Safety /3
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 of -10°C (plasma machines 0°C) to +40°C and
•a relative air humidity 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

General
AL/1
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.

1 Technical data
1/1
inverter
with
S-sign
TIG 150 DC TIG 200 DC
powerSinus
TIG 250 DC TIG 300 DC
Adjustable:
Welding current 5A - 150A 5A - 200A 5A - 250A 5A - 300A
Welding voltage 10,1V - 26V 10V - 28V 10V - 30V 10V - 32V
Mains voltage
(tolerances) 1x230V (15%;-40%)
1x240V (10%;-40%) 1x230V (15%;-40%) 1x240V (10%;-40%) 3x400V (20%;-25%) 3x415V (15%;-25%) 3x400V (20%;-25%) 3x415V (15%;-25%)
Mains frequency 50/60Hz
Mains fuse
slow-blow 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 35mm250mm2
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
classification IP 23
Insulation class H
Machine cooling fan
Torch cooling gas
Total weight 23kg 22kg 26kg 26kg
Dimensions (LxBxH) 450x290x400mm 530x260x400mm 480x355x400mm 480x355x400mm
Constructed to
standards VDE 0544 und EN 60974-1
SAll welding machines which carry the Smarking are constructed in accordance
with VDE 0544 (EN 60974-1) 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 Smarking are constructed in accordance with VDE 0544
(EN 60974-1) and can be used in working with increased hazard of electrical shock

2 Operating elements
2/1
F
E
D
J
C
H
A
G
B
I
K
H
A
L
K
F
B
I
G
E
D
J
C
Fig. 1
inverter
TIG 150 DC Fig. 2
inverter
TIG 200 DC
powerSinus
H
F
A
K
B
G
I
E
L
D
C
J
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
91
0
ArcForce
10
RUTIL
3
2CELL
BASISCH
7
8
Rotary dial arcforcing device (only TIG 200/250/300)