EWM PHW 100 Operating Instructions Manual Download Page 1 | Manualshive

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Operating instructions

EN

welding torch

PHW 100

099-008232-EW501 Observe additional system documents!

26.05.2020

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Summary of Contents for PHW 100

Page 1: ...Operating instructions EN welding torch PHW 100 099 008232 EW501 Observe additional system documents 26 05 2020...

Page 2: ...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 f...

Page 3: ...1 Hydrogen 15 5 7 2 Plasma gas 15 5 7 3 Shielding gas 16 5 7 4 Forming gas 16 5 8 Tables of current carrying capacity 17 5 8 1 Current carrying capacity and plasma gas quantities for standard nozzle 1...

Page 4: ...maintenance tasks 29 6 2 3 Annual test inspection and testing during operation 29 6 3 Disposing of equipment 29 7 Rectifying faults 30 7 1 Checklist for rectifying faults 30 7 2 Vent coolant circuit 3...

Page 5: ...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...

Page 6: ...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...

Page 7: ...c 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 main...

Page 8: ...rview PHW 100 8 099 008232 EW501 26 05 2020 4 Machine description quick overview 4 1 PHW 100 Figure 4 1 Item Symbol Description 0 1 Grip plate 2 Torch trigger 3 Back cap 4 Collet housing 5 Torch body...

Page 9: ...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...

Page 10: ...the use of a power source in conjunction with a circulating air or recooling unit Trade and industry use the diversity of this process 5 3 1 Procedure In physics a plasma is an electrically conductive...

Page 11: ...h cooling system Coolant mixtures Mixtures with other liquids or the use of unsuitable coolants result in material damage and ren ders the manufacturer s warranty void Only use the coolant described i...

Page 12: ...mbol Description 0 1 Water cooling 2 Shielding gas 3 Shielding gas exit Part of the heat is released to the cooling system of the welding torch over the plasma nozzle and gas lens and part of the shie...

Page 13: ...25 55 105 Figure 5 4 Item Symbol Description 0 1 Quick connect nipple 9 mm 0 35 inch Coolant feed blue 2 Quick connect nipple 9 mm 0 35 inch Coolant return red 3 Quick connect nipple 5 mm 0 2 inch Sh...

Page 14: ...e Control cable assembly 7 Connector plug 4 mm 0 16 inch Pilot arc current 5 6 Ultraviolet radiation WARNING Risk of injury due to radiation or heat Arc radiation can lead to skin and eye injuries Con...

Page 15: ...ight weekend 5 7 1 Hydrogen Follow the safety precautions below to exclude the risk of explosion during plasma welding with hydrogen in the gas mixture 1 Pipes hoses screw connections and machines thr...

Page 16: ...ity 2 deep penetration small seam width 3 medium penetration 4 shallow penetration large seam width A reduced quantity of plasma gas pos 2 to 4 results in a softer arc characteristic and a shallow pen...

Page 17: ...100 plasma nozzles electrode at the negative po le electrode diameter 1 0 1 5 2 4 mm 0 04 0 06 0 09 inch The plasma gas used is generally Argon Diameter of plasma nozzles Amount of plasma gas Electrod...

Page 18: ...1 5 2 4 mm 0 06 0 09 inch 100 A 5 8 3 Current carrying capacity and plasma gas quantities for the angled nozzle Diameter of plasma nozzles Amount of plasma gas Electrode diameter Current 0 5 mm 0 02...

Page 19: ...is worn electrodes and or nozzles To prevent damage to the welding torch the replacement of wear parts must not be delayed unnecessarily Before starting any work on the welding torch the welding syst...

Page 20: ...de insert 4 from the plasma nozzle Clean the sealing surfaces and check for defective components before inserting new parts Check the sealing ring of the gas nozzle 5 and replace if damaged Rub the se...

Page 21: ...following guide values apply to the electrodes of the welding torch Nozzle type Electrode diameter Tip bevel Max length Min Length Standard nozzle 1 5 mm 0 06 inch 30 on both sides 51 mm 2 00 inch 30...

Page 22: ...inding angle Figure 5 14 The more pointed the grinding cone the deeper the penetration The wider the grinding cone the shallower the penetration 5 9 3 2 Removal and reassembly of the electrode with mo...

Page 23: ...crewed from the collet housing and the collet is pushed forward out of the housing This is only necessary in case of maintenance 5 9 3 3 Setting the electrode gap Figure 5 16 Item Symbol Description 0...

Page 24: ...09 inch 2 4 mm 0 09 inch 14 5 mm 0 57 inch 2 6 mm 0 10 inch 3 0 mm 0 12 inch 14 0 mm 0 55 inch 19 0 mm 0 75 inch 22 0 mm 0 87 inch 26 0 mm 1 02 inch 3 2 mm 0 13 mm 5 9 3 6 Guide values for basic sett...

Page 25: ...32 EW501 26 05 2020 25 5 9 3 7 Installation of the electrode with the electrode clamping unit removed Figure 5 18 Item Symbol Description 0 1 Electrode 2 Sealing ring of the gas nozzle 3 Torch body 4...

Page 26: ...he electrode 1 with the blunt side first from the front through the torch body into the collet Push the pre set electrode setting gauge from the front over the electrode into the torch body Screw the...

Page 27: ...5 10 2 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 Figure 5 20 Increased current load and a torch p...

Page 28: ...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 o...

Page 29: ...nd testing at www ewm group com 6 3 Disposing of equipment Proper disposal The machine contains valuable raw materials which should be recycled and electronic com ponents which must be disposed of Do...

Page 30: ...nections Check the plasma nozzle for firm seating Overload Check and correct welding current setting Use a more powerful welding torch No arc ignition Incorrect ignition type setting Setting the tungs...

Page 31: ...nsation hydrogen in the gas tube Purge hose package with gas or replace Increased wear Increased electrode wear Plasma gas purity too low Electrode distance too high Insufficient water cooling Gas sup...

Page 32: ...current pilot arc 2 10 A Plasma gas Argon Shielding gas Argon Argon Hydrogen approx 95 5 Argon Helium Heli um Argon Active gas mixture Torch cooling water max Coolant pressure 4 5 bar min Coolant flo...

Page 33: ...n Item no ELECTRODE ADJUSTMENT GAUGE Electrode setting gauge 094 008262 00000 ON Adap Microplasma new Adapter for connecting a welding torch with screw coupling to Microplasma 25 55 105 092 003539 000...

Page 34: ...WM 100 20A 0 8 Plasma nozzle 4 094 008244 00000 PNOZZ PWH PWM 100 25A 1 0 Plasma nozzle 4 094 008245 00000 PNOZZ PWH PWM 100 30A 1 2 Plasma nozzle 4 094 008246 00000 PNOZZ PWH PWM 100 40A 1 4 Plasma n...

Page 35: ...008261 00000 TUNGSTEN SPEC 1 5 mm X 51 mm Tungsten electrode special 8 094 008951 00000 TUNGSTEN SPEC 1 5 mm X 72 mm Tungsten electrode special 8 094 008283 00000 TUNGSTEN SPEC 2 4 mm X 72 mm Tungsten...

Page 36: ...ndix Searching for a dealer 36 099 008232 EW501 26 05 2020 11 Appendix 11 1 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners world...

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