EWM Microplasma 105-2 PG RC Operating Instructions Manual Download Page 1

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Operating instructions

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

Summary of Contents for Microplasma 105-2 PG RC

Page 1: ...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...

Page 2: ...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...

Page 3: ...elding 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...

Page 4: ...on 50 5 9 Machine configuration menu 51 5 9 1 Selecting changing and saving parameters 51 6 Maintenance care and disposal 55 6 1 General 55 6 1 1 Cleaning 55 6 1 2 Dirt filter 55 6 2 Maintenance work...

Page 5: ...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 oper...

Page 6: ...ch 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 gre...

Page 7: ...al 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 Befor...

Page 8: ...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 excessiv...

Page 9: ...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...

Page 10: ...acement 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 m...

Page 11: ...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 powe...

Page 12: ...nd 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 i...

Page 13: ...ination 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...

Page 14: ...Machine description quick overview Front view side view from left 14 099 007033 EW501 4 1 2022 4 Machine description quick overview 4 1 Front view side view from left Figure 4 1...

Page 15: ...r 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 coupl...

Page 16: ...iew Rear view side view from right 16 099 007033 EW501 4 1 2022 4 2 Rear view side view from right The device configuration shown may differ in case of an additional ex works options or retrofitting o...

Page 17: ...e 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...

Page 18: ...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 parame...

Page 19: ...g 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...

Page 20: ...ss 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 prog...

Page 21: ...n settings are done exclusively via the con trol button 4 Balance signal light Pulse balance 5 Electrode diameter signal light Ignition optimisation TIG tungsten balling basic setting 6 Gas post flow...

Page 22: ...lue and signal light flash Then turn to set the parameter value During welding parameter setting the parameter value to be set flashes in the left hand display A param eter abbreviation or a deviation...

Page 23: ...are displayed after welding and the settings are then changed e g welding cur rent the display will switch to the relevant nominal values The parameters that can be set in the machine control functio...

Page 24: ...The machine must not be operated in the open air and must only be set up and operated on a suitable stable and level base The operator must ensure that the ground is non slip and level and provide suf...

Page 25: ...e structural parts of the workpiece as welding current return lead 5 1 4 Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults in the arc flic...

Page 26: ...2 Use an individual welding lead to the workpiece for each welding machine Figure 5 2 Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loops Always keep lead...

Page 27: ...heck that all welding current connections are firmly secured and electrical connections are in perfect condition Set up attach or suspend all conductive power source components such as casing transpor...

Page 28: ...be connected to a one phase system with two conductors and an earthed neutral conductor Figure 5 5 Legend Item Designation Colour code L Outer conductor brown N Neutral conductor blue PE Protective co...

Page 29: ...as cylinder 4 Cylinder valve Before connecting the pressure regulator to the gas cylinder open the cylinder valve briefly to blow out any dirt Tighten the pressure regulator screw connection on the ga...

Page 30: ...s not ignited and no welding process is being carried out Shielding and plasma gas setting can be checked without welding current flowing currentless and set if required Activation of the gas test but...

Page 31: ...it voltage supply 5 8 pole connection socket Cooling unit control lead Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings Return line red to quick connec...

Page 32: ...ption 0 1 Welding torch cooling unit 2 Quick connect coupling red coolant return 3 Quick connect coupling blue coolant supply Lock connecting nipples of the cooling water tubes into the corresponding...

Page 33: ...10 Item Symbol Description 0 1 Welding torch 2 Torch hose package 3 Pilot current connection socket Plasma welding torch nozzle potential 4 Workpiece lead 5 Quick connect coupling red coolant return 6...

Page 34: ...of the cooling water tubes into the corresponding quick connect couplings Return line red to quick connect coupling red coolant return and supply line blue to quick connect coupling blue coolant supp...

Page 35: ...e protective gas line onto the quick connect coupling type 20 Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings Return line red to quick connect couplin...

Page 36: ...dure Figure 5 12 5 2 2 Pilot arc Ignite pilot arc Figure 5 13 Switching off the pilot arc The pilot arc must be switched off and the gas post flow time plasma gas waited for before switching off the w...

Page 37: ...pted to the welding process at four operating points 1 Pilot arc standby current during the welding pause 2 Pilot arc ignition current before welding 3 Pilot arc process current during welding 4 Pilot...

Page 38: ...Setting selection Expert menu Start time duration of start current Slope time main current to secondary current Slope time secondary current to main current End current time duration of end current Pi...

Page 39: ...can also be set to meet individual requirements e g for thin panels a smaller diameter is recommended to reduce the ignition energy The electrode diameter setting determines the minimum current limit...

Page 40: ...ignites and the welding current is increased depending on the operat ing mode set to the ignition or main current set c Lift off the torch and swivel to the normal position Ending the welding process...

Page 41: ...umber of pa rameters shown may be limited e g if a function is deactivated ENTER EXIT Figure 5 20 Display Setting selection Expert menu Start time duration of start current Slope time main current to...

Page 42: ...or the intermediate hose package AW has been changed The resistance value of the cables can be set directly or can be aligned by the power source In the delivery state the cable resistance is set to t...

Page 43: ...n 0 m and 60 m The new value is immediately saved without requiring further confirmation If no value is shown on the right hand display then measurement failed The measurement must be repeated 4 Resto...

Page 44: ...n the weld pool that have a positive effect on the gap bridging The required pulse parameters are automatically defined by the machine control If required the function can be disabled by pressing the...

Page 45: ...ause setting 4s Figure 5 27 Pulse edge setting The and pulse edges can be set in the Expert menu TIG see 5 3 4 chapter 5 4 1 3 Pulsed welding in the upslope and downslope phases The pulse function can...

Page 46: ...the plasma force arc force occurring at high currents which al lows you to achieve a constricted arc with concentrated heat input Unlike thermal pulsing no times are set a frequency and the balance a...

Page 47: ...rent Ipuls a balance and a frequency having been defined first The predefined ampere current average value is decisive and the pulse current Ipuls is defined by the parameter as a percentage of the av...

Page 48: ...code for the access block Select parameter and enter the previously selected number code 0 999 Disable access block Set parameter to access block disabled The only way to disable the access block is...

Page 49: ...ower source To use this function jumper 1 must be unplugged on PCB T320 1 in the welding machine Contact open welding current off F Output 0V Reference potential G NC Not assigned H Output Uist Actual...

Page 50: ...lt settings for welding data monitoring Update function for new welding parameters 5 8 1 Connection Equipment damage or faults may occur if the PC is connected incorrectly Not using the SECINT X10USB...

Page 51: ...machine configuration menu 5 9 1 Selecting changing and saving parameters ENTER l 0 A A B A A A A EXIT NAVIGATION A B B B B B B B B B B B B B B B B B B B B A B B B B B B B B B B B B B B B B B B B B B...

Page 52: ...solute Welding current setting as a percentage of the main current ex works Non latched operation version C Function enabled Function disabled ex works RINT X12 JOB control for automation solutions on...

Page 53: ...me to activation of the power saving mode in case of inactivity Setting disabled or numerical value 5 60 min Operating mode switching via interface for automated welding Non latched Special non latche...

Page 54: ...Service menu Any changes to the service menu should be agreed with the authorised service person nel Reset to factory setting Disabled ex works Reset the values in the machine configuration menu Compl...

Page 55: ...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 spa...

Page 56: ...ollers on a regular basis depending on the degree of soiling 6 2 2 Monthly maintenance tasks Visual inspection Casing damage front rear and side walls Wheels and their securing elements Transport elem...

Page 57: ...tem 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 c...

Page 58: ...ervice personnel if required Warning code Possible cause Remedy 1 Machine excess temperature Allow the machine to cool down 2 Half wave failures Check process parameters 3 Welding torch cooling warnin...

Page 59: ...p if necessary 8 Gas error Check the gas supply 9 Secondary overvoltage Switch the machine off and on If the error persists no tify Service 10 PE error 11 FastStop position Slope Acknowledge error sig...

Page 60: ...s that are stored will be replaced by the factory settings To reset the welding parameters or machine settings to the factory settings select parameter in the service menu see 5 9 chapter 7 4 Display...

Page 61: ...kage with gas or replace Welding torch overheated Loose welding current connections Tighten power connections on the torch and or on the workpiece Tighten contact tip correctly Overload Check and corr...

Page 62: ...0 99 Protection class Overvoltage category Contamination level 3 Insulation class protection classification H IP 23 Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambient te...

Page 63: ...on level 3 Insulation class protection classification H IP 23 Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambient temperature 4 25 C to 40 C Machine cooling Torch cooling...

Page 64: ...ntamination level 3 Insulation class protection classification H IP 23 Residual current circuit breaker Type B recommended Noise level 3 70 dB A Ambient temperature 4 25 C to 40 C Machine cooling Torc...

Page 65: ...F 5 l 094 000530 00005 KF 23E 200 Coolant 10 C 200 litres 094 000530 00001 KF 37E 5 Coolant up to 20 C 4 F 5 l 094 006256 00005 KF 37E 200 Coolant 20 C 200 l 094 006256 00001 TYP1 Frost protection tes...

Page 66: ...in current AMP to secondary current AMP 0 00 s 0 00 20 0 Secondary current percentage of AMP 50 1 200 Secondary current absolute depending on power source A Pulse pause time 0 01 s 0 00 20 0 Slope tim...

Page 67: ...Appendix Searching for a dealer 099 007033 EW501 4 1 2022 67 10 2 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldwide...

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