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Accessories

Welding torch cooling system

099-007033-EW501

4.1.2022

Accessories

Performance-dependent accessories like torches, workpiece leads, electrode holders or interme-

diate hose packages are available from your authorised dealer.

9.1 Welding torch cooling system

Type

Designation

Item no.

Cool 50 MPW50

Cooling module with centrifugal pump

090-008818-00502

HOSE BRIDGE UNI

Tube bridge

092-007843-00000

RK1

Reverse cooling unit

094-002283-00000

UKV4SET 4M

Hose connection set

092-000587-00000

9.1.1 Coolant - type blueCool

Type

Designation

Item no.

blueCool -10 5 l

Coolant up to -10 °C (14 °F), 5 l

094-024141-00005

blueCool -10 25 l

Coolant up to -10 °C (14 °F), 25 l

094-024141-00025

blueCool -30 5 l

Coolant up to -30 °C (22 °F), 5 l

094-024142-00005

blueCool -30 25 l

Coolant up to -30 °C (22 °F), 25 l

094-024142-00025

FSP blueCool

Frost protection tester

094-026477-00000

9.1.2 Coolant - type KF

Type

Designation

Item no.

KF 23E-5

Coolant up to -10 °C (14 °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 tester

094-014499-00000

9.2 Options

Type

Designation

Item no.

ON Filter TG.04/K.02

Contamination filter for air inlet

092-002698-00000

ON WAK

TG.03/TG.04/TG.09/K.02

Wheel assembly kit

092-001356-00000

9.3 Interface

Type

Designation

Item no.

RINT X12 STANDARD

Robot interface

090-008291-00000

ON PLUG SET RINT X12

Optional EWM plug set, retrofit kit for RINT X12

092-001822-00000

RA5 19POL 1x 5M

Connection cable, 19-pole, 5 m

092-001569-00005

FRV 7POL 10 m

Extension/connecting cable

092-000201-00000

9.4 Computer communication

Type

Designation

Item no.

PC300 XQ Set

PC300.Net welding parameter software kit incl. ca-

ble and SECINT X10 USB interface

090-008777-00000

9.5 General accessories

Type

Designation

Item no.

Maxex AR/MIX 200bar 30m³

G1/4"

Pressure regulator

096-000000-00000

Maxex Hydrogen 200bar 30m³

G3/8"L

Pressure regulator

096-000001-00000

2M-G1/4"+G3/8"/DIN EN 559 Gas tube, 2 m

092-000525-00001

GH 2X1/4'' 2M

Gas hose

094-000010-00001

Содержание Microplasma 105-2 PG RC

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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