EWM Microplasma 25-2 PG RC User manual

Operating instructions
EN
Welding machine
Microplasma 25-2 PG RC
Microplasma 55-2 PG RC
Microplasma 105-2 PG RC
099-007033-EW501
Observe additional system documents!
4.1.2022

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 re-
pair the machine.
• Technical changes due to further development in machine technology may lead to a differ-
ing welding behaviour.
In the event of queries on installation, commissioning, operation or special conditions at the in-
stallation 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/en/specialist-dealers.
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 ac-
cepted 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
Tel.: [phone], Fax: -244
Email: [e-mail]
www.ewm-group.com
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.
Data security
The user is responsible for backing up data of all changes from the factory setting. The user is liable for
erased personal settings. The manufacturer does not assume any liability for this.

Contents
Notes on using these operating instructions
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1 Contents
1Contents .......................................................................................................................................... 3
2For your safety ............................................................................................................................... 5
2.1 Notes on using these operating instructions .......................................................................... 5
2.2 Explanation of icons ............................................................................................................... 6
2.3 Safety instructions .................................................................................................................. 7
2.4 Transport and installation .................................................................................................... 10
3Intended use ................................................................................................................................. 12
3.1 Applications .......................................................................................................................... 12
3.2 Software version .................................................................................................................. 12
3.3 Documents which also apply ............................................................................................... 12
3.3.1 Warranty ............................................................................................................... 12
3.3.2 Declaration of Conformity ..................................................................................... 12
3.3.3 Welding in environments with increased electrical hazards ................................. 12
3.3.4 Service documents (spare parts and circuit diagrams) ........................................ 12
3.3.5 Calibration/Validation............................................................................................ 12
3.3.6 Part of the complete documentation ..................................................................... 13
4Machine description – quick overview ...................................................................................... 14
4.1 Front view / side view from left ............................................................................................ 14
4.2 Rear view / side view from right ........................................................................................... 16
4.3 Machine control – Operating elements ................................................................................ 18
4.3.1 Overview of control sections ................................................................................ 18
4.3.1.1 Control section A ................................................................................... 19
4.3.1.2 Control section B ................................................................................... 20
4.4 Operating the machine control ............................................................................................. 22
4.4.1 Main screen .......................................................................................................... 22
4.4.2 Welding power setting .......................................................................................... 22
4.4.3 Welding parameter setting in the operation sequence ......................................... 22
4.4.4 Setting advanced welding parameters (Expert menu) ......................................... 22
4.4.5 Changing basic settings (machine configuration menu) ...................................... 22
4.4.6 Welding data display ............................................................................................ 23
4.4.7 Setting the welding current (absolute/percentage) ............................................... 23
5Design and function ..................................................................................................................... 24
5.1 Transport and installation .................................................................................................... 24
5.1.1 Ambient conditions ............................................................................................... 24
5.1.2 Machine cooling .................................................................................................... 24
5.1.3 Workpiece lead, general ....................................................................................... 25
5.1.4 Notes on the installation of welding current leads ................................................ 25
5.1.5 Stray welding currents .......................................................................................... 27
5.1.6 Mains connection .................................................................................................. 28
5.1.6.1 Mains configuration ............................................................................... 28
5.1.7 Shielding and plasma gas supply ......................................................................... 28
5.1.7.1 Pressure regulator connection .............................................................. 29
5.1.7.2 Connection of shielding gas and plasma gas hose .............................. 29
5.1.7.3 Gas test ................................................................................................. 30
5.1.7.4 Automatic gas post-flow ........................................................................ 30
5.1.8 Welding torch cooling system ............................................................................... 31
5.1.8.1 Cooling unit connection ......................................................................... 31
5.1.8.2 Connection of external recooling unit.................................................... 32
5.1.9 Welding torch and workpiece line connection ...................................................... 33
5.1.9.1 Plasma welding ..................................................................................... 33
5.1.9.2 TIG welding ........................................................................................... 34
5.2 Plasma welding .................................................................................................................... 36
5.2.1 Welding task selection .......................................................................................... 36
5.2.1.1 Setting welding procedure .................................................................... 36
5.2.2 Pilot arc ................................................................................................................. 36
5.2.2.1 Adjust pilot arc currents ........................................................................ 37
5.2.3 Expert Menu (Plasma) .......................................................................................... 38
5.3 TIG welding .......................................................................................................................... 39

Contents
Notes on using these operating instructions
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5.3.1 Welding task selection .......................................................................................... 39
5.3.2 Arc ignition ............................................................................................................ 40
5.3.2.1 HF ignition ............................................................................................. 40
5.3.2.2 Liftarc ..................................................................................................... 40
5.3.2.3 Automatic cut-out .................................................................................. 40
5.3.3 TIG antistick .......................................................................................................... 40
5.3.4 Expert menu (TIG) ................................................................................................ 41
5.3.5 Aligning the cable resistance ................................................................................ 42
5.4 Recurring welding tasks ....................................................................................................... 43
5.4.1 Pulse welding ........................................................................................................ 44
5.4.1.1 Automated pulses .................................................................................. 44
5.4.1.2 Thermal pulsing ..................................................................................... 44
5.4.1.3 Pulsed welding in the upslope and downslope phases ......................... 45
5.4.1.4 Metallurgical pulsing (kHz pulsing) ........................................................ 46
5.4.2 Average value pulse welding ................................................................................ 47
5.5 Power-saving mode (Standby) ............................................................................................. 47
5.6 Access control ...................................................................................................................... 48
5.7 Interfaces for automation ..................................................................................................... 48
5.7.1 Automation interface ............................................................................................. 49
5.7.2 RINT X12 robot interface ...................................................................................... 49
5.7.3 BUSINT X11 industrial bus interface .................................................................... 50
5.8 PC interface ......................................................................................................................... 50
5.8.1 Connection ............................................................................................................ 50
5.9 Machine configuration menu ................................................................................................ 51
5.9.1 Selecting, changing and saving parameters......................................................... 51
6Maintenance, care and disposal ................................................................................................. 55
6.1 General ................................................................................................................................. 55
6.1.1 Cleaning ................................................................................................................ 55
6.1.2 Dirt filter ................................................................................................................. 55
6.2 Maintenance work, intervals................................................................................................. 56
6.2.1 Daily maintenance tasks ....................................................................................... 56
6.2.2 Monthly maintenance tasks .................................................................................. 56
6.2.3 Annual test (inspection and testing during operation) .......................................... 56
6.3 Disposing of equipment ........................................................................................................ 57
7Rectifying faults ............................................................................................................................ 58
7.1 Warnings .............................................................................................................................. 58
7.2 Error messages .................................................................................................................... 59
7.3 Resetting welding parameters to the factory settings .......................................................... 60
7.4 Display machine control software version ............................................................................ 60
7.5 Checklist for rectifying faults ................................................................................................ 60
8Technical data ............................................................................................................................... 62
8.1 Microplasma 25-2 PG RC .................................................................................................... 62
8.2 Microplasma 55-2 PG RC .................................................................................................... 63
8.3 Microplasma 105-2 PG RC .................................................................................................. 64
9Accessories .................................................................................................................................. 65
9.1 Welding torch cooling system .............................................................................................. 65
9.1.1 Coolant - type blueCool ........................................................................................ 65
9.1.2 Coolant - type KF .................................................................................................. 65
9.2 Options ................................................................................................................................. 65
9.3 Interface ............................................................................................................................... 65
9.4 Computer communication .................................................................................................... 65
9.5 General accessories ............................................................................................................ 65
10 Appendix ....................................................................................................................................... 66
10.1 Parameter overview – setting ranges .................................................................................. 66
10.2 Searching for a dealer .......................................................................................................... 67

For your safety
Notes on using these operating instructions
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2 For your safety
2.1 Notes on using 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 sym-
bol.
• 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 warn-
ing symbol.
• The risk is explained using a symbol on the edge of the page.
Technical aspects which the user must observe to avoid material or equipment damage.
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 hold
Switch
Incorrect / Invalid
Turn
Correct / Valid
Numerical value – adjustable
Input
Signal light lights up in green
Navigation
Signal light flashes green
Output
Signal light lights up in red
Time representation (e.g.: wait 4 s / ac-
tuate)
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
Safety instructions
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2.3 Safety instructions
WARNING
Risk of accidents due to non-compliance with the safety instructions!
Non-compliance with the safety instructions can be fatal!
• Carefully read the safety instructions in this manual!
• Observe the accident prevention regulations and any regional regulations!
• Inform persons in the working area that they must comply with the regulations!
Risk of injury from electrical voltage!
Voltages can cause potentially fatal electric shocks and burns on contact. Even low volt-
ages can cause a shock and lead to accidents.
• Never touch live components such as welding current sockets or stick, tungsten or wire
electrodes!
• Always place torches and electrode holders on an insulated surface!
• Wear the full personal protective equipment (depending on the application)!
• The machine may only be opened by qualified personnel!
• The device must not be used to defrost pipes!
Hazard when interconnecting multiple power sources!
If a number of power sources are to be connected in parallel or in series, only a tech-
nical specialist may interconnect the sources as per standard IEC 60974-9:2010: Instal-
lation and use and German Accident Prevention Regulation BVG D1 (formerly VBG 15)
or country-specific regulations.
Before commencing arc welding, a test must verify that the equipment cannot exceed
the maximum permitted open circuit voltage.
• Only qualified personnel may connect the machine.
• When taking individual power sources out of operation, all mains and welding current leads
must be safely disconnected from the welding system as a whole. (Hazard due to reverse
polarity voltage!)
• Do not interconnect welding machines with pole reversing switch (PWS series) or machines
for AC welding since a minor error in operation can cause the welding voltages to be com-
bined, which is not permitted.
Risk of injury due to radiation or heat!
Arc radiation can lead to skin and eye injuries.
Contact with hot workpieces and sparks can lead to burns.
• Use hand shield or welding helmet with the appropriate safety level (depends on the appli-
cation).
• Wear dry protective clothing (e.g. hand shield, gloves, etc.) in accordance with
the applicable regulations of your country.
• Persons who are not directly involved should be protected with a welding curtain or suitable
safety screen against radiation and the risk of blinding!

For your safety
Safety instructions
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WARNING
Risk of injury due to improper clothing!
During arc welding, radiation, heat and voltage are sources of risk that cannot be
avoided. The user has to be equipped with the complete personal protective equipment
at all times. The protective equipment has to include:
• Respiratory protection against hazardous substances and mixtures (fumes and vapours);
otherwise implement suitable measures such as extraction facilities.
• Welding helmet with proper protection against ionizing radiation (IR and UV radiation) and
heat.
• Dry welding clothing (shoes, gloves and body protection) to protect against warm environ-
ments with conditions comparable to ambient temperatures of 100 °C or higher and arcing
and work on live components.
• Hearing protection against harming noise.
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure
when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by welding or cutting!
Fire hazard!
Due to the high temperatures, sparks, glowing parts and hot slag that occur during
welding, there is a risk of flames.
• Be watchful of potential sources of fire in the working area!
• Do not carry any easily inflammable objects, e.g. matches or lighters.
• Ensure suitable fire extinguishers are available in the working area!
• Thoroughly remove any residue of flammable materials from the workpiece prior to starting
to weld.
• Only further process workpieces after they have cooled down. Do not allow them to contact
any flammable materials!

For your safety
Safety instructions
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CAUTION
Smoke and gases!
Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent
vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to
the ultraviolet radiation of the arc!
• Ensure that there is sufficient fresh air!
• Keep solvent vapour away from the arc beam field!
• Wear suitable breathing apparatus if appropriate!
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
According to IEC 60974-10, welding machines are divided into two classes of electro-
magnetic compatibility (the EMC class can be found in the Technical
data) > see 8 chapter:
Class A machines are not intended for use in residential areas where the power supply comes
from the low-voltage public mains network. When ensuring the electromagnetic compatibility of
class A machines, difficulties can arise in these areas due to interference not only in the supply
lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas, includ-
ing residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur
although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the surround-
ing area, the user must consider the following: (see also EN 60974-10 Appendix A)
• Mains, control, signal and telecommunication lines
• Radios and televisions
• Computers and other control systems
• Safety equipment
• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing
aid
• Calibration and measuring equipment
• The immunity to interference of other equipment in the surrounding area
• The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
• Mains connection, e.g. additional mains filter or shielding with a metal tube
• Maintenance of the arc welding system
• Welding leads should be as short as possible and run closely together along the ground
• Potential equalization
• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,
it should be connected by means of suitable capacitors.
• Shielding from other equipment in the surrounding area or the entire welding system
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which
could affect the correct functioning of electronic equipment such as IT or CNC devices,
telecommunication lines, power cables, signal lines and pacemakers.
• Observe the maintenance instructions > see 6.2 chapter!
• Unwind welding leads completely!
• Shield devices or equipment sensitive to radiation accordingly!
• The correct functioning of pacemakers may be affected (obtain advice from a doctor if nec-
essary).

For your safety
Transport and installation
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CAUTION
Obligations of the operator!
The respective national directives and laws must be complied with when operating the
machine!
• Implementation of national legislation relating to framework directive 89/391/EEC on the in-
troduction of measures to encourage improvements in the safety and health of workers at
work and associated individual guidelines.
• In particular, directive 89/655/EEC concerning the minimum safety and health requirements
for the use of work equipment by workers at work.
• The regulations applicable to occupational safety and accident prevention in the country
concerned.
• Setting up and operating the machine as per IEC 60974.-9.
• Brief the user on safety-conscious work practices on a regular basis.
• Regularly inspect the machine as per IEC 60974.-4.
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode hold-
ers, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the ma-
chine is switched off.
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains net-
work. For some types of machines, connection restrictions or requirements relating to the maxi-
mum possible line impedance or the necessary minimum supply capacity at the interface with the
public network (Point of Common Coupling, PCC) can therefore apply. In this respect, attention is
also drawn to the machines' technical data. In this case, it is the responsibility of the operator,
where necessary in consultation with the mains network operator, to ensure that the machine can
be connected.
2.4 Transport and installation
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders can cause seri-
ous injuries!
• Observe the instructions from the gas manufacturer and any relevant regulations concern-
ing the use of compressed air!
• Do not attach any element to the shielding gas cylinder valve!
• Prevent the shielding gas cylinder from heating up.

For your safety
Transport and installation
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CAUTION
Risk of accidents due to supply lines!
During transport, attached supply lines (mains leads, control cables, etc.) can cause
risks, e.g. by causing connected machines to tip over and injure persons!
• Disconnect all supply lines before transport!
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself
during movement and set up. Tilt resistance is guaranteed up to an angle of 10° (ac-
cording to IEC 60974-1).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
Risk of accidents due to incorrectly installed leads!
Incorrectly installed leads (mains, control and welding leads or intermediate hose pack-
ages ) can present a tripping hazard.
• Lay the supply lines flat on the floor (avoid loops).
• Avoid laying the leads on passage ways.
Risk of injury from heated coolant and its connections!
The coolant used and its connection or connection points can heat up significantly dur-
ing operation (water-cooled version). When opening the coolant circuit, escaping cool-
ant may cause scalding.
• Open the coolant circuit only when the power source or cooling unit is switched off!
• Wear proper protective equipment (protective gloves)!
• Seal open connections of the hose leads with suitable plugs.
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
Accessory components and the power source itself can be damaged by incorrect connection!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
• Comprehensive descriptions can be found in the operating instructions for the relevant ac-
cessory components.
• Accessory components are detected automatically after the power source is switched on.
Protective dust caps protect the connection sockets and therefore the machine against dirt and
damage.
• The protective dust cap must be fitted if there is no accessory component being operated on
that connection.
• The cap must be replaced if faulty or if lost!

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 stand-
ards applicable for use in industry and trade. It may only be used for the welding proce-
dures 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 ex-
pert personnel!
• Do not improperly modify or convert the equipment!
3.1 Applications
Arc welding machine for microplasma DC welding with HF ignition (contactless). Suitable for operation
with automated welding torches.
It may be possible to expand the range of functions by using accessories (see the documentation in the
relevant chapter).
3.2 Software version
These instructions apply to the following software version:
07.0410
The software version of the machine control can be displayed in the machine configuration menu
(menu Srv) > see 5.9 chapter.
3.3 Documents which also apply
3.3.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information regarding
warranty, maintenance and testing at www.ewm-group.com!
3.3.2 Declaration of Conformity
This product corresponds in its design and construction to the EU directives listed in the decla-
ration. The product comes with a relevant declaration of conformity in the original.
The manufacturer recommends carrying out the safety inspection according to national and in-
ternational standards and guidelines every 12 months.
3.3.3 Welding in environments with increased electrical hazards
Power sources with this marking can be used for welding in an environment with increased elec-
trical hazard (e.g. boilers). For this purpose, appropriate national or international regulations
must be followed. The power source must not be placed in the danger zone!
3.3.4 Service documents (spare parts and circuit diagrams)
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)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.3.5 Calibration/Validation
An original certificate is enclosed with the product. The manufacturer recommends calibration / validation
at intervals of 12 months.

Intended use
Documents which also apply
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3.3.6 Part of the complete documentation
This document is 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 compo-
nents, especially the safety instructions!
Figure 3-1
The illustration shows a general example of a welding system.
Item
Documentation
A.1
Robot interface
A.2
Control
A.3
Power source
A.4
Cooling unit
A.5
Mechanisation component
A.6
Welding torch
A
Complete documentation

Machine description – quick overview
Front view / side view from left
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4 Machine description – quick overview
4.1 Front view / side view from left
Figure 4-1

Machine description – quick overview
Front view / side view from left
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Item
Symbol
Description 0
1
Ready for operation signal light
Signal light on when the machine is switched on and ready for operation
2
Main Switch
Switching the machine on or off.
3
Workpiece lead connection socket
4
Pilot current connection socket
Plasma welding torch nozzle potential
5
7-pole connection socket (digital)
For connecting digital accessory components
6
Cooling air inlet
Dirt filter optional > see 6.1.2 chapter
7
Carrying handle
8
Machine feet
9
Quick connect coupling (red)
coolant return
10
Quick connect coupling (blue)
coolant supply
11
Quick connect coupling plasma gas (plug nipple type 20)
Connection to welding torch
12
Quick connect coupling shielding gas (coupling type 20)
Connection to welding torch
13
Welding current connection socket, welding torch
14
Machine control > see 4.3 chapter
15
Plasma gas flow regulator
Control and display of gas flow volume
16
Shielding gas flow regulator
Control and display of gas flow volume

Machine description – quick overview
Rear view / side view from right
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4.2 Rear view / side view from right
The device configuration shown may differ in case of an additional ex works options or retrofitting
options > see 9 chapter.
Figure 4-2

Machine description – quick overview
Rear view / side view from right
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Item
Symbol
Description 0
1
19-pole mechanised welding interface (analogue)
> see 5.7.1 chapter
2
7-pole connection socket (digital)
For connecting digital accessory components
3
Key button, Automatic cutout
Wire feed motor supply voltage fuse
(press to reset a triggered fuse)
4
7-pole connection socket
For connecting Wire feed unit
5
8-pole connection socket
Cooling unit control lead
6
G1/4" connecting nipple, shielding gas connection
Connection to the pressure reducer
7
Connecting nipple G1/4“ plasma gas, inlet
Connection to pressure regulator
8
Quick connect coupling (red)
coolant return
9
Quick connect coupling (blue)
coolant supply
10
Carrying handle
11
Machine feet
12
Cooling air outlet
13
Mains connection cable > see 5.1.6 chapter
14
5-pole connection socket
Cooling unit voltage supply
15
Connection socket (9-pole) - D-Sub
PC interface > see 5.8 chapter

Machine description – quick overview
Machine control – Operating elements
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4.3 Machine control – Operating elements
4.3.1 Overview of control sections
For description purposes, the machine control has been divided into two sections (A, B) to ensure
maximum clarity. The setting ranges for the parameter values are summarised in the parameter
overview section > see 10.1 chapter.
Figure 4-3
Item
Symbol
Description 0
1
Control section A
> see 4.3.1.1 chapter
2
Control section B
> see 4.3.1.2 chapter

Machine description – quick overview
Machine control – Operating elements
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4.3.1.1 Control section A
Figure 4-4
Item
Symbol
Description 0
1
Welding data display (3-digit)
Displays the welding parameters and the corresponding values > see 4.4.6 chapter
2
Gas test push-button > see 5.1.7.3 chapter
3
Operating mode / power-saving mode push-button
---------- Latched
------- Non-latched
------- spotArc spot welding procedure – signal light turns green
------- spotmatic spot welding procedure –signal light turns red
--------- Press button for long interval to put machine into power-saving mode.
Activate one of the operating elements to reactivate.
4
Pulsed welding push-button
---- TIG automated pulsing (frequency and balance)
--------- Signal light turns green: Pulsing (thermal pulsing)
--------- Signal light lights up in red: kHz pulsing (metallurgical pulsing)
5
Filler wire welding signal light
For machines with filler wire only (AW)
6
TIG ignition type signal light
Signal light on: Lift arc ignition active/HF start off. You can switch the ignition type in the
Expert menu (TIG) > see 5.3.2 chapter.
7
Character function signal light
Indicates that it is possible to weld in an environment with major electric hazards, such
as in boilers. Service must be informed if this signal light is not on.

Machine description – quick overview
Machine control – Operating elements
20
099-007033-EW501
4.1.2022
Item
Symbol
Description 0
8
Coolant fault signal light
Signals pressure loss or low coolant level in the coolant circuit.
9
Hold
Signal light Status display
After each completed welding task, the last values used in the welding process for the
welding current and welding voltage are shown on the displays, and the signal light will
be on
10
Excess temperature signal light
In case of excess temperature, temperature monitors de-activate the power unit, and
the excess temperature control lamp comes on. Once the machine has cooled down,
welding can continue without any further measures.
11
Access control active signal light
Signal light is on when access control is active on the machine con-
trol > see 5.6 chapter.
12
Programme signal light (only for machine series “RC”)
Display of the current program number in the welding data display.
13
Pilot arc push-button
------ Ignition process started (signal light turns green)
------ Pilot arc on (signal light on red)
------ Plasma gas flows (signal light turns green)
14
Welding procedure push-button
--------- Plasma welding
--------- TIG welding
15
Display switching push-button
kW ------- Welding power display
V --------- Welding voltage display
JOB ------ Display and setting of the JOB number with the control button
4.3.1.2 Control section B
Figure 4-5
Item
Symbol
Description 0
1
Parameter selection push-button, left
The welding sequence parameters are selected one after another in an anti-clockwise
direction. For control systems without this button settings are done exclusively via the
control button.