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Rectifying faults

Checklist for rectifying faults

099-008232-EW501

26.05.2020

Rectifying faults

All products are subject to rigorous production checks and final checks. If, despite this, something fails to

work at any time, please check the product using the following flowchart. If none of the fault rectification

procedures described leads to the correct functioning of the product, please inform your authorised dea-

ler.

7.1 Checklist for rectifying faults

The correct machine equipment for the material and process gas in use is a fundamental

requirement for perfect operation!

Legend

Symbol

Description



Fault/Cause



Remedy

Welding torch overheated



Insufficient coolant flow





Check coolant level and refill if necessary





Eliminate kinks in conduit system (hose packages)



Vent coolant circuit

> see 7.2 chapter



Loose welding current connections



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 tungsten electrode



Regrind or replace the tungsten electrode



Ignition type: Select “HF start”. Depending on the machine, the setting is defined by the chan-

geover switch for ignition types or the

parameter in one of the machine menus (see the

“Control operating instructions”, if applicable).

Bad arc ignition



Material inclusions in the tungsten electrode due to contact with filler material or workpiece



Regrind or replace the tungsten electrode



Clean and change gas nozzle





Insufficient plasma gas quantity



Pilot arc current too low

Pilot arc ignites but no main arc forms



Distance between workpiece and torch too high





Decrease distance to workpiece



Contaminated workpiece surface



Clean the workpiece surface



Bad current transfer on ignition





Setting the tungsten electrode



Incompatible parameter settings



Check settings and correct if necessary

Содержание PHW 100

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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