instruction manual electrode mma – tig

instruction manual electrode mma – tig
MMA - TIG
INSTRUCTION MANUAL
Rev. 1.2 - Novembre 2014
INSTRUCTION MANUAL
SCHEMAS
Pag. 4
TECHNICAL TABLES
Pag. 14
DECLARATION OF CONFORMITY
Pag. 17
2
Pag. 13
MODELS
Duty Cycle Rif.
15% 20%
25%
35% 40%
60% 60% 3Ph
70%
TIG Tab. 01 Tab. 02 Tab. 03 Tab. 04 Tab. 05 Tab. 06/A Tab. 06/B
Tab. 07 Tab. 08 Pag. 14
Pag. 14
Pag. 14
Pag. 14
Pag. 15
Pag. 15
Pag. 15
Pag. 16
Pag. 16
DIRECTIVES
● 2006/42/CEE (Machinery)
● 2006/95/CEE ( Low Voltage)
● 2004/108/CEE (EMC)
● EN 60974-1 ed. 07/01 (Arc Welding Equipment)
● EN 60974-7 ed. 11/00 (Torches)
● EN 60974-10 ed. 11/03 (EMC)
● 2002/95/CE 2002/96/CE (RAEE)
● 2003/108/CE (RAEE)
● 2002/95/CE (RoHS)
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INTRODUCTION
Congratulations for your choice. Our products have been designed, manufactured and tested to comply
with the latest European Community requirements. The arc welding power system, if used correctly, can be
operated in very safe conditions while if the prescribed safety norms are not observed it could cause serious
damages to people and objects.
TABLE OF CONTENTS
1 --- ELECTROMAGNETIC COMPATIBILITY
1.1 INTRODUCTION
1.2 ASSESSMENT OF POTENTIAL ELECTROMAGNETIC PROBLEMS
1.3 METHODS OF REDUCING EMISSIONS
2 --- INSTRUCTION FOR USE
2.1 USE INSTRUCTIONS
2.2 PRELIMINARIES BEFORE USE
3 --- SAFETY
3.1 INTRODUCTION
3.2 GENERAL PRECAUTIONS
4 --- GENERAL DESCRIPTIONS AND PRODUCT SPECIFICATIONS
4.1 INTRODUCTION
4.2 SYSTEM DESCRIPTION
4.3 TECHNICAL SYMBOLS EXPLANATION
4.4 PROTECTION DEVICES
5 --- INSTALLATION PROCEDURE
5.1 UNPACKING AND SETUP
5.2 STARTUP PROCEDURE
5.3 GENERAL NOTES
6 --- OPERATION
6.1 DESCRIPTION OF CONTROL PANEL
6.2 COATED ELECTRODE WELDING
6.3 TIG WELDING
6.4 TIG HF WELDING
8 --- CUSTOMER CARE - WARRANTY
8 --- SPARE PARTS
IMPORTANT
TO BE READ BEFORE USING THIS DEVICE
The following instructions should be read by all concerned before installing or using this device. In case of
any doubt contact your distributor or directly the producer to get all the informations that may be needed.
1 --- ELECTROMAGNETIC COMPATIBILITY
FROM EN 60974-10 “EMC product standard for arc welding equipment”
1.1 INTRODUCTION
The user is responsible for installing and using the welding equipment according to the manufacturers instructions. If electromagnetic disturbances are detected then it shall be responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this
remedial action may be as simple as earthing the welding circuit. In other cases it could involve constructing
4
an electromagnetic screen enclosing the power source and the work complete with associated input filters.
In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements
should only be authorized by a person who is competent to asses whether the changes increase the risk of
injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other
equipment.
1.2 ASSESSMENT OF POTENTIAL ELECTROMAGNETIC PROBLEMS
1.2.1 Assessment of area. Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a) Other supply cables, control cables, signaling and telephone cables above, below and adjacent to the welding equipment;
b) Radio and television transmitters and receivers;
c) Computer and other control equipment;
d) Safety critical equipment, e.g. guarding of industrial equipment;
e) The health of the people around, e.g. the use of pacemakers and hearing aids;
f) Equipment used for calibration or measurement;
g) The immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) The time of the day that welding or other activities are to be carried out. The size of the surrounding area
to be considered will depend on the structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.
1.3 METHODS OF REDUCING EMISSIONS
1.3.1 Mains supply. Welding equipment should be connected to the mains supply according to the manufacturers recommendations. If interference occurs, it may be necessary to take additional precautions such
as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently
installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous
throughout its length. The shielding should be connected to the welding power source so that good electrical
contact is maintained between the conduit and the welding power source enclosure.
1.3.2 Maintenance of the welding equipment. The welding equipment should be routinely maintained according to the manufacturers recommendations. All access and service doors and covers should be closed
and properly fastened when the welding equipment is in operation. The welding equipment should not be
modified in any way except for those changes and adjustment covered in the manufacturers instructions. In
particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according
to the manufacturers recommendations.
1.3.3 Welding cables. The welding cables should be kept as short as possible and should be positioned close
together, running at or close to the floor level.
2 --- INSTRUCTION FOR USE
2.1 USE INSTRUCTIONS
For a correct use of the appliance it is important to follow the indications hereunder.
Do not expose to water dripping, to heat sources, avoid the use in anomalous situations.
The interventions of extraordinary maintenance are not necessary; in any case these last must be executed
by authorized service centers.
Every tampering causes the expiry of the guarantee.
During the storage and the transport, the temperature must be comprised between -25 and +55 centigrade
degrees.
2.2 PRELIMINARIES BEFORE USE
Generators should only be used by trained personnel.
5
Generators have been planned for the use in particularly hard environments with temperatures from -20
+40 degrees centigrade
and with humidity:
max 50% up to +40 degrees centigrade
max 90% up to +20 degrees centigrade
1) Check that the mains voltage is the one indicated on the data plate.
2) Never cover the generator with objects (towels, cloths ecc.), as this will jeopardise the proper ventilation
and therefore its operation.
3) Do not put the unit in positions limiting its airflow.
4) Use in environments with temperatures below 40 degrees centigrades.
5) Do not use in polluted environments, i.e. in presence of dusts, acids and/or salts, ferrous or metal dusts.
6) Check that the available power of the network is adequate to the one required for the proper operation
of the machine.
7) The degree of protection from the external agents of these generators is IP21/23, namely the protection
against the vertical fall
of water-droplets and protection against foreign bodies.
Therefore, it is absolutely necessary that:
A) No foreing bodies pass through the loopholes.
B) It is not placed in muddy or damp areas or dipped into liquids.
The generator must never be used without its covering. Besides being harmful to the same unit, it is certainly dangerous for the operator.
3 --- SAFETY
3.1 INTRODUCTION
Arc welding processes as developed after many years of welding experience can be used with a high degree
of safety provided that proper care and attention is given to common sense practices and to manufacturer’s
recommended methods. It is therefore imperative that management and safety personnel make sure that
all personnel who will operate or maintain the welding equipment be given the opportunity to read this information.
3.2 GENERAL PRECAUTIONS
3.2.1 Prevention of burns sparks, slag, hot metal and radiations produced by the welding arc can be seriously
damaging to the eyes and skin. As the operator or any other person comes close to the welding area, the
level of exposure increases rapidly. Proper protective clothing and equipment must be worn by the operator
and any other persons working in the vicinity of the arc. Gauntlet gloves designed for use in welding, safety
shoes, and a hat are required. Flame retardant clothing which covers all exposed areas and cuffless trousers
to prevent entry of sparks and slag are recommended. Proper safety goggles or glasses with side shields of
the appropriate welding lens shade MUST be worn to protect the operator’s eyes from radiant energy and
flying sparks or hot metal.
3.2.2 Fire prevention Since electric welding arc produces hot metal, sparks, and slag, precautions must be
taken to prevent fire and/or explosions. Make sure that appropriate fire extinguishing equipment is available
in the immediate welding area. All combustible materials must be removed from the immediate welding area
to a distance of at least 10 meters(35 feets) away. Never arc weld empty containers which have held toxic
or potentially explosive materials. Those containers must be thoroughly cleaned prior to welding. Never arc
weld in an atmosphere which contains heavy concentrations of dust, flammable gas, or combustible liquid
vapors(such as gasoline). After each welding operation make sure to let welded material to cool down before
touching it or putting it in contact with combustible or flammable materials.
3.2.3 Toxic Fumes Proper precautions must be exercised to prevent the exposure of the operator or others in
the surrounding area to possible toxic fumes which may be generated during electric are welding. Certain chlorinated solvents will decompose under ultraviolet radiations to form phosgene gas. Care must be exercised
to avoid the use of these solvents on materials being weld with electric arc welding equipment. Containers
of these solvents and other degreasing agents must be removed from the immediate area near the welding
6
arc. Metals coated with or containing significant amounts of lead, cadmium, zinc, mercury, and beryllium can
produce harmful concentration of toxic fumes when subject to electric arc welding operations. Adequate
local exhaust ventilation must be used or the operator must be wearing special equipment to guarantee a
supply of fresh air as a respirator or air supplied helmet. Do not weld metals coated with materials which
emit toxic fumes unless 1) the coating is removed prior to welding, 2) the area is adequately ventilated, or 3)
the operator is supplied with fresh-air breathing equipment.
3.2.4 Radiation Ultra-violet radiations created by the arc may be harmful to the eyes and burn the skin;
it is therefore imperative to wear protective clothing and helmet. Contact lenses should not be used
as the intense heat coming from the arc may cause them to stick to the cornea. The mask used during welding should be equipped with grade DIN 10 safety lenses at least and they should immediately be replaced whenever damaged or broken. Since the arc may damage the eyes it is considered dangerous up to a distance of 15 meters (50 feets) and it should never be locked at with the naked eye.
3.2.5 Electric shock All electric shocks are potentially fatal and therefore live wires and/or parts should never
be touched. Insulation must be kept from the piece to be welded and from the ground by wearing insulation
gloves and clothing. Garments such as gloves, shoes, hats, clothings and body must be kept dry at all times
and it is to be avoided working in humid or wet areas. Never touch or hold the piece to be welded by hand;
if the slightest electric shock is felt, welding should be stopped immediately; the unit is not to be used until
the problem is identified and solved by qualified personnel. Frequently inspect the primary power cable for
damage or cracking of the cover and replace immediately damaged cable. Disconnect power supply cable
from mains before replacing cables or before removing unit covers. Always replace any damaged parts of the
unit, with original material. Never short out or in any other way defeat the safety interlock devices and make
sure that the power supply line is equipped with an efficient earth plug. Make sure that the work table is
connected to a good earth ground. Any maintenance is to be carried out by qualified personnel only that is
to be aware of the risks due to dangerous voltages necessary for the operation of the unit.
3.2.6 Pacemaker Person wearing electronic life support devices (such as pacemaker) should consult with
their doctor before going near arc welding, cutting, gouging or spot welding operations in order to make sure
that magnetic fields associated with high currents do not affected their devices.
4 --- GENERAL DESCRIPTIONS AND PRODUCT SPECIFICATIONS
4.1 INTRODUCTION
The welding power supplies deliver constant current and are designed with INVERTER technology using components having high performance and high reliability and can use for stick electrode and TIG welding.
4.2 SYSTEM DESCRIPTION
The power supply is built on a single main board with the control logics on separate interchangeable hybrid
boards which give the system a very high degree of reliability and simplify maintenance and service. The power module uses an INVERTER working at a frequency higher than 80 kHz with a very low dynamic response
time (500 millisecond) resulting in an extremely smooth welding characteristic which gives easier starting,
more homogeneous droplet size, better penetration and smoother bead appearance.
4.3 TECHNICAL SYMBOLS EXPLANATION
• IEC 974 / EN60974 The power supply is manufactured according to these international standards.
• S/N...... Serial number to be stated for any question relating to the unit.
Single phase stating frequency converter-transformer-rectifier.
•
Dropping characteristic.
• • MMA
Suitable for welding with coated electrodes.
• TIG Suitable for TIG welding.
Secondary no-load voltage.
• Uo • X
Duty-factor percentage: The duty-factor expresses the percentage of 10 minutes in which the power supply • I2
can operate at a without overheating
Welding current.
7
• U2 Secondary voltage with welding current I2.
• U1 Nominal supply voltage.
• 1 ̴ 50/60Hz Single phase supply 50 or 60 Hz..
• I1 Absorbed current at the corresponding welding current I2.
When using the power supply for TIG welding, value by 1.6
• IPxx Grade of protection of metal frame. • S
Suitable for working in high-risk areas.
• NOTE
The power supply has been designed to operate in areas with grade 3 pollution (IEC 664).
4.4 PROTECTION DEVICES
4.4.1 Overheating and main supply anomalies protection. The power supply is protected by a device installed in such a way as to act in case of overheating and/or main supply anomalies. When this device intervenes,
the unit stops supplying current but the cooling fan keeps working. The acting of the device is shown by the
LED turning on. The turning off of the LED signals the resumed ability of the unit to be in operating conditions.
5 --- INSTALLATION PROCEDURE
5.1 UNPACKING AND SETUP
Unpack the unit and carefully inspect it for shipping damages. Any claims for damages which may have occurred in transit must be filed by the purchaser with the carrier and in order not to loose any right to file such a
claim no clean receipt should be signed but a mention should be made to reserve the right to file a claim for
transit damages that can be discovered only after unpacking. All communications regarding this equipment
must indicate the model and serial number located on the back of the power supply. After unpacking place
the unit in a properly ventilated, possibly undusted area, making sure that the air flow near the cooling slots
in not obstructed.
WARNING: it is extremely important not to restrict the air flow around the unit since this may cause the unit
to over heat and could possibly damage internal parts. Keep at least 200 mm of unrestricted space on all sides of the unit. Do not Place any filter device or cover over the air intake slots of the power supply as this will
void the warranty. NOTE: if the unit is carried over shoulder make sure that the air intake slots on the frame
are not obstructed.
5.2 STARTUP PROCEDURE
This unit must be installed by skilled personnel. All connections must conform to the existing rules and in full
compliance with safety regulations (CENELEC HD 427).
5.3 GENERAL NOTES
Before using this power supply, carefully read the CENELEC standards HD 407 and HD 433, check insulation
of cables, electrode holder clamp, sockets and plugs and make sure that the length and section of welding
cables are compatible with current used:
Up to 5 mt. cable section 16 mm2 min.
From 5 mt. to 20 mt. cable section 25 mm2 min.
From 20 mt. to 30 mt. cable section 35 mm2 min.
6 --- OPERATION
6.1 DESCRIPTION OF CONTROL PANEL
On the front panel one finds:
1. Current adjustment knob
2. Electrode and earth clamp cable connectors
3. Welding current LED indicator (ok if on)
4. AC power input fault
(voltage outside the + - 10% of 220 V range) or overheating condition LED indicator (OK if off).
8
6.2 COATED ELECTRODE WELDING
This power supply is suitable for welding with all types of electrodes. For the cellulose ones (AWS 6010), only
specific power supply can be used, see the technical tables.
Use electrode holder clamps in compliance with the safety standards and without projecting tightening
screws.
Make sure that the main switch on the back is on 0 position or that main supply plug is not inserted in main
outlet then connect welding cables in accordance with polarity indications given by the electrode manufacturer.
The welding circuit should not be deliberately placed in direct or indirect contact with protection wire if not
on piece to be welded. If earthing is deliberately made on the work piece by means of protection wire, the
connection must be as direct as possible, with the wire having a section at least equal to the welding current
return wire and connected to the piece being worked on, in the same place as the return wire, using the return wire terminal or a second earth terminal closely.
All possible precautions must be taken in order to avoid stray currents. Check that the input supply voltage
matches the voltage indicated on the power supply technical specification tag.
Connect main supply cable: when mounting a plug make sure that its capacity is adequate and that the
yellow-green wire of the mains cable is connected to the earth plug pin. The capacity of the magnetothermic
switch or the fuses in the mains supply line should be higher than or equal to current I1 absorbed by the unit.
The absorbed current I1 is determined by reading the technical specifications on the unit as corresponding
to the main supply voltage U1.
Any extension cord should have a section adequate for the absorbed current I1.
Turn on the power supply with the main switch on the back of the unit.
WARNING: ELECTRIC SHOCK CAN KILL.
Do not touch live electric parts.
Do not touch weld output terminals when unit is energized.
Do not touch torch or electrode and earth clamp at the same time. Set current according to the electrode
diameter, welding position and type of joint to be welded. When finished welding always remember to turn
the main switch off and to remove electrode from electrode holder.
6.3 TIG WELDING (for all models)
This power supply is suitable for TIG welding stainless steel, iron and copper.
Connect earth cable wire to positive (+) pole of welding unit and connect terminal clamp to working piece as
close as possible to power supply, making sure there is a good electrical contact.
Use proper TIG torch and connect power wire to negative pole of welding unit.
The welding circuit should not be deliberately in direct or indirect contact with protection wire if not on piece
to be welded.
If earthing is deliberately made on the workpiece by means of protection wire, the connection must be as
direct as possible, with the wire having a section at least equal to that of the welding current return wire and
connected to the piece being worked on, in the same place as the return wire, using the return wire terminal
or a second earth terminal closely.
All possible precautions must be taken in order to avoid stray current.
Connect gas pipe to pressure reducer output connected to an ARGON cylinder and regulate gas flow adjusting the regulation knob on the torch handle. Inside the torch handle a valve allows the gas flow to be shut.
Use a 2% thoriated tungsten electrode having a diameter chosen according the negative electrode direct
current (Argon) value as follows:
up to 60A Ø 1 mm
from 60A to 180A Ø 1.6 mm
from 180A to 250A Ø 2,4 mm
The electrode tip should be prepared for welding according to procedure indicated hereafter (Fig. 01 Pag. 54).
Check the main supply voltage to match the voltage on the power supply technical specification tag.
Connect main supply cable: when mounting a plug make sure that its capacity is adequate and that the
yellow-green wire of the mains cable is connected to the earth plug pin.
The capacity of the magnetothermic switch or the fuses in the mains supply line should be higher than or
9
equal to current I1 absorbed by the unit. The absorbed current I1 is determined by dividing by 1.6 the value
stated on the table.
Any extension cord should have a section adequate for the absorbed current I1.
Set welding current based on the weld to be performed then adjust the gas flow with knob on torch handle.
Start the arc, by contact, with a quick scratch on the surface to be welded.
CAUTION do not use commercial ignition devices.
The TIG torch is designed in such a way that using the valve on the torch body the gas flow can continue after
the weld is performed to protect the electrode while it is still hot.
After the proper amount of time /few seconds) the gas flow can be stopped by shutting the valve on the torch
handle.
Once welding is finished the unit is to be turned off and the gas cylinder valve is to be closed.
6.4 TIG HF (for HF models only)
On the front of the control panel the following can be found
1. Welding current regulation potentiometer
2. Holder/torch and earth sockets
3. Current manual setting/remote control lever switch
4. TIG/MMA welding lever switch
5. Digital A-meter to read the current draw upon arc ignition
6. Current rise time regulation knob
7. Current fall time regulation knob
8. Current Post-gas time regulation knob
9. Socket for remote control connection
10. 2 time/4 time operation mode lever switch
11. Gas outlet
12. Torch push-button connector
Five LED warning lights on the left side of the front panel signal the following, respectively:
A. Generator under voltage (GREEN LED)
B. Line surge or overheating (YELLOW LED)
C. High frequency igniter on (RED LED)
D. Argon gas supply (GREEN LED)
E. Inverter on (YELLOW LED)
This welding machine is suitable for TIG welding of inox steel, iron and copper. Connect the earth cable connector to the positive terminal of the welding machine and the clamp as close as possible to the welding
spot, making sure good electrical contact is made. Use the special TIG torch (for HF ). The welding circuit must
not be put into direct or indirect contact with the safety conductor except on the work piece. If the work
piece is deliberately earthed through the safety conductor having a section equal to or greater than that of
the welding current return conductor connected to the work piece at the same point as the return conductor
with the return conductor clamp or another earth clamp next to it. Take the utmost care to avoid welding
stray currents. Connect the gas inlet on the rear panel of the generator to the output of the pressure reducer connected to an argon cylinder. Adjust the gas pressure by means of the flow meter. Use a 2% thoriated
tungsten electrode chosen according to the following table:
up to 60 A ‌ Ø 1.0 mm
from 60 A to 180 A Ø 1.6 mm
from 180A to 250A Ø 2,4 mm
The preparation of the electrode tip should be done as explained in schemas section (Fig. 01 Pag. 54). Check
that the supply voltage is the one indicated on the technical specification plate of the welding machine. Connect the power cable. Switch on the welding machine by closing the power switch on the rear panel; adjust
the current according to the job to be carried out, set switch 2/4T to 4T mode, set the current rise and fall
times as preferred and the post-gas time; then bring the electrode within 3 mm approximately from the work
piece and let out a pulse upon pressing the torch push-button (press and release it). The following will occur:
10
1. Gas is let out and the relevant LED lights up. (LED D)
2. The high frequency circuit stars (within a second or so and ignites an arc) (LED C)
3. Current rises until it reaches the value set, as the A-meter will show.
At this stage, the generator will keep the arc going until another pulse is applied upon pressing the torch
push-button. The following will then occur:
4. Current starts falling.
5. The arc nearly extinguishes itself.
6. The post-gas phase starts.
It a relatively long current fall time was set, and one does not wish to wait for automatic extinction of the arc,
another pulse may be applied to stop welding at any moment.
However, if the 2T mode selected, the torch push-button must be kept depressed during arc ignition, current
rise and welding, and then released to allow current fall and arc extinction.
This generator uses an inverter of the seventh generation (the latest available, as there are no other singlecard technology inverters of the same power at 90 kHz) and therefore incorporates the following exclusive
capabilities and devices.
TIG PROCESS
- Very low-noise, fully electronic, solid-state high frequency igniter (no spark points as found in older igniters).
- Safety device which switches off the igniter and resets the cycle if an arc is not ignited within about fifteen
seconds.
After welding, do not forget to switch off the welding machine off and shut the gas cylinder valve.
Electrode preparation. It is necessary to use special attention when preparing the electrode tip grinding it so
as to obtain vertical makings as shown in figure (see in schemas section):
CAUTION: HOT FLYING METAL PARTICLES can injure personnel, start fires and damages equipment.
TUNGSTEN CONTAMINATION can lower weld quality. Shape tungsten electrode tip only on grinder with proper guards in
a safe location wearing proper face, hand and body protection. Shape tungsten electrode tip on a fine grit, hard abrasive wheel
used only for tungsten shaping. Grind the end of the tungsten electrode to a taper for a length of 1.5 to 2 electrode diameters.
STAND BY
-Special saving circuit that, if the generator is not used within 30 s from ignition, disables all function and
reduces power consumption to only 25 W (no greater than a light bulb’s), thus eliminating any undue internal heating, increasing generator life and, more important, saving 1 kWh every four hours of operation. Of
course, as soon as the generator starts a welding phase the device automatically re-enables all the generator
functions preventing any inconvenience.
8 ---- CUSTOMER CARE - WARRANTY
Fixing and Warranty
Answering the assistance and warranty needs is part of our work, and since we take great care to create professional
products capable of satisfying the most demanding requests, we bring ourselves into play with participation and a great
sense of responsibility, in order to solve the smallest snags that might occur. We do this willingly and passionately, while
respecting precise rules that are necessary to safeguard the rights of all the concerned parts:
What we recognize
• We commit ourselves to recognize any manufacturing defect for two years, starting from the purchase moment. The
date written on the document bears witness to the purchase (receipt or invoice) and must explicitly indicate the purchased product description.
• Immediate and free replacement including all shipping costs (there and back – within the European boundaries) if the
fault is detected within 15 days from the purchase date.
• The warranty includes the free faulty products replacement.
• The warranty includes the labour necessary for the faulty products replacement.
• The warranty always includes the transport costs for the welder return.
What we do not recognize
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• We do not recognize for any reason the warranty on items without a document proving the purchase (receipt or invoice) or whose purchase document presents generic values or descriptions that cannot be directly traced back to our
products.
• The warranty does not include the costs to dispatch the welder to the technical support centre from the 16th day after
the purchase.
• The warranty does not include the fixing costs if the welder has been opened or tampered with by other people.
• The warranty does not include the fixing costs if the welder shows clear impact evidences.
• The warranty does not include the fixing costs if the welder has clear signs of wrong feeding.
Special cases subject to inspection
The warranty is recognized subject to confirmation and after specific evaluations on a case-by- case basis if the purchase
date indicated on the receipt is 4 days higher than the machine production date. The latter is easily found from the first
two figures composing the serial number SN, which is printed on the data plate of each machine.
And what if the machine is out of warranty?
When a machine is received by the assistance centre EPS, it is analysed in order to evaluate an average maximum cost,
that is then notified to the customer. This is a completely free estimate in case the fixing is then authorised. Whereas
should the notified cost not meet the customer’s interest, the analysis carried out on the machine will be paid (25.00 €
+ VAT). The return for items out of warranty upon fixing payment (or payment of the analysis only if the machine is not
fixed) always implies that the transport costs are at consignee’s expense.
Do you think it impossible to manage the assistance from Italy?
Nowadays the transport times and costs within the European Community are similar to those of your countries, so that
shipping a machine from your country to Italy costs a few Euros by the most known carriers, and even less by postal services. The service is fast, efficient and with the confidence that you will get a perfect fixing, the one that can be provided
only by the manufacturer.
Every product that has been fixed at our assistance centre undergoes a test bench with on-load and off-load simulations, in order to verify its conformity to the safety regulations; then all the current and working values setting are
restored and an actual final welding test is performed, together with the verification of all the working parameters.
WARNING! All technical interventions, as well as the possible warranty cases involving EPS products, are managed directly by the manufacturer. There are no recognized assistance centres and there is no external company officially being
licensed to perform fixings or replacements, for which the manufacturer does not respond!
EPS products assistance centre:
VIVA ELETTRONICA! S.R.L.
Via delle Industrie 218/A
17012 Albissola Marina (SV) ITALIA
[email protected]
8 ---- SPARE PARTS
ALL EPS ORIGINAL PARTS ARE AVAILABLE
FOR CONSULTATION AND PURCHASE ON-LINE IN THE WEB SITE
WWW.EPS-INVERTER.COM
For the replacement of both mechanical and electronic components we always recommend the use of original parts,
available and at disposal for purchase on-line at any time directly from the website www.eps-inverter.com, where in correspondence of each model it can be found the relevant section with dedicated spare parts, inclusive codes and pictures,
constantly updated and containing all technical modifications made ​​over the years.
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+
R39
R2
D1
MF5
G
MF2
MF6
G
MF7
G
R7
C10
R57
TA1
C28
C28
R11
made in Italy
C12
L1
D8
D7
D9
DL1
R39
R16
R17
C14
C22
TR4
R7
R6
R5
R4
T2
TA1
TA1
C16
C9
D1
DZ1
R20
R9
R8
GND
D2
R23
R33
EW2804 Rev.0 made in Italy
R25
IC1
C10
R24
D11
R31
T3
C
D6
R33
R35
R34
E
R26
+C13
C11
DZ2
R27
+
FAN
CN1
R27
R60
D1 2
D5
D6
R25
E
GND
+
C10
R7
C15
C16
R9
R6
R26
R13
R14
D1
C
R30
Dz2
C
C14
R29
R31
B
T4
C11
R8
R14
C7
R13
R1
R2
CN2
R41
DL1
CN2
4X1
DL2
R5
C9
R4
G
MF8
R28
RV1
FAN
CN1
+ +
C3
C2
R2
R1
C4
C1
C4
C2
+
-
G
-
MF7
G
B
MF6
R28
PT1
E
G
7
MOS
R37
R36
D3
MF5
C6
MF4
C8
R19
R18
-
C5
G
MF3
8
T4
DIO
G
MF2
C7
E
B
R40
COM
G
MF1
B
C
R36
+
+
G
D2
1
+
+
MOS
E
R38
R34
+
DIO
~
R37
-
COM
+
-
T5
C
+
R15
C13
P2
~
2
R3
RL1
PT1
TR3
P2
+ +
+
C3
C6
R17
R16
P1
TR2
RV32
+
C5
TR3
~
C
+
Dz1
D4
MF5
MF10
~
B
+ +
+
+
R20
MF4
MF9
MF3
MF8
CN3
T4
E
+
+
+
R23
R21
- -
MF7
MF2
R36
R35
TR1
+
MADE IN ITALY
D10
EW 4001
TR4
T2
R34
R57
R53
R53
TR2
C
D4
R59
C19
R30
R29
TR1
C20
T3
D7
D8
D9
D11
D10
R12
B
D10
R19
D9
R18
D8
D3
D7
R10
C
E
C12
R21
R11
R22
EW4001 REV.0 04-05-13 MADE IN ITALY
R11
D5
R10
FAN CN1
C15
R9
R56
R6
C27
TA1
C27
C11
R10
R22
B
D4
D11
R8
R11
C10
R24
C
R33
GND
G
R56
D14
R37
Dz2
R47
TR2
R35
RL1
B
MF8
G
R28
TR2
R3
E
MF4
R30
P1
C
R14
TR4
G
MF3
R29
MF1
MF6
B
R19
T2
Dz2
G
MF1
EW 2804
B
+
+
G
D2
D15
E
D3
R19
R1
R18
E
R27
R31
R48
R49
EW 2980
R24
R23
R22
R21
R20
Dz1
D17
B
R52
R46
Ri2
R13
TR3
C
TA1
D
+
P1
C2
C3
R39
R38
C22
Dz1
R20
R26
++
R42
+
S
DL2
MOS
D6
MF3
D7
C14
DIO
D
R51
1
COM
R25
E
R45
C20
G
DL1
R17
C
D5
R50
R9
C26
MF4
G
R16
15
T3
C27
S
EW 2900
R5
C25
CN1
GND
R36
S
D
R4
B
C35
MOS
B
G
C9
MF2
D8
B
C
E
T3
S
D
R40
E
DIO
G
IC1
R15
C7
DL2
MTH1
D13
MF1
D6
C4
C1
R3
DL1
IB1
1
COM
D5
R41
C
C34
C19
E
B
T2 C
E
RV32
PT1
C6
+
+
R33
++
++
Ri1
C13
RL1
PT1
C17
TR4
~
P2
RV1
R24
R43
R44
+
-
+
C23
IC1
++
++ ++
++ ++
C18
+
R12
~
+
+
++
TR1
R34
C21
C16
~
FUS 1
-
P2
RL1
TR1
+
+
~
+
TR3
+
EW 2900
+
EW 2980
P1
C15
C21
++
MF8
MF10
D
G
S
MF5
D
G
MF6
S
C
EB
C
EB
C
EB
C
EB
CN3
R47
CN1
+
DIS.00017
COD. E6900017
C31
C8
R57..R63
VAR2
COD. E6800016
DIS. 00016
DL2
D8
D11
T2
Ri3
TR3
DZ2
MF14
R26
E
DL1
R23
VAR3
Ri1
MF7
MF13
MF12
R41
R42
C25
R22
C10
G
23/04/13 Rv.0
MF11
C21
R49
L1
R20
D
GND
TIG
R28
D3
R29
C
EB
C
EB
C
B
R27
TR4
TR5
DZ3
D4
D12
T3
R50..R56
Ri2
TR2
Ri4
by MARIO
R31
D5
R30
R
S
C20
C19
R45
1
D13
D10
SH1
D6
MTH1 80 C N.C.
13
C
MF4
EW5220
MF9
G
IB1
CN2
MTH3
GND
TIG
80C NC
D
R44
MTH2
S
MAX-CU
C22
C23
DIS. 00020
COD. E6900020
G
MF3
C9
D2
D
C12
IB2
R40
R37
C13
DIS. 00018
COD. E6900018
MF2
S
C11
R32 R65 R66 R67
R21
G
R38
R35
RV1
R34
C17
D
DUTY
C24
R19
R18
R17
R16
R15
R14
R13
R12
R11
R10
R9
R8
R7
R6
R4
R5
R2
R3
MF1
D1
S
PT1
R39
C14
+
+
G
2
R48
R43
R36
TA1
TA1
R33
MAX
DZ1 V ING
C7
D
C15
++
C18
R24
C6
1
IC1
C4
C2
1
RV4
R68
TR1
C3
S
D7
OC1
+
+
FUS 1
CN1
++
-RL1
C5
RV3
I. MAX.
DIS. 00019
COD. E6900019
R25
VAR1
GND
TIG
P2
C30
MAX I.TA RV.2
T1
TP1
C16
++
R1
P1
MAX. CU.
EW 5220 - 5002
E
Tab. 01
Duty cycle 15%
Main voltage
Frequency
Cos φ
Efficiency
Current range
Off load voltage
Output current 35%
Output current 15%
Absorbed power 35%
Absorbed power 15%
Main current 35%
Main current 15%
Tab. 02
Duty cycle 20%
Main voltage
Frequency
Cos φ
Efficiency
Current range
Off load voltage
Output current 35%
Output current 20%
Absorbed power 35%
Absorbed power 20%
Main current 35%
Main current 20%
Tab. 03
Duty cycle 25%
Main voltage
Frequency
Cos φ
Efficiency
Current range
Off load voltage
Output current 35%
Output current 20%
Absorbed power 35%
Absorbed power 20%
Main current 35%
Main current 25%
14
110 A
230 VAC
50/60 Hz
0.99
0.85
5 – 110 A
80 V
90 A
110 A
2.3 KVA
2.8 KVA
11.3 A
13.6 A
230 VAC
50/60 Hz
0.99
0.85
8 - 100 A
60 V
65 A
100 A
1,9 KVA
3,2 KVA
8,3 A
13,6 A
230 VAC
50/60 Hz
0.99
0.85
8 – 130 A
60 V
85 A
130 A
2.6 KVA
4,3 KVA
11,3 A
18,6 A
80 A
230 /115 VAC
50/60 Hz
0.99
0.85
5-80 A
80 V
65 A
80 A
1.8 KVA
2.1 KVA
8.3/17 A
10.5/21 A
100 A
230/115 VAC
50/60
0.99
0.85
5 – 100 A
80 V
85 A
100 A
2.3 KVA
2.8 KVA
11.3/22.6 A
13.6/27.2 A
130 A
230 VAC
50/60 Hz
0.99
0.85
5 – 130 A
80 V
115 A
130 A
3.3 KVA
3.8 KVA
16.1 A
18.6 A
Tab. 04
Duty cycle 35%
Main voltage
Frequency
Cos φ
Efficiency
Current range
Off load voltage
Output current 60%
Output current 35%
Absorbed power 60%
Absorbed power 35%
Main current 60%
Main current 35%
230 VAC
50/60 Hz
0.99
0.85
8 – 160 A
60 V
115 A
160 A
3.7 KVA
5,5 KVA
16 A
24 A
130 A
230 VAC
Hz 50/60 Hz
0.99
0.85
5 – 130 A
80 V
115 A
130 A
3.3 KVA
3.8 KVA
16.1 A
18.6 A
230 VAC
50÷60 Hz
0.99
0.85
5 – 130 A
80 V
85 A
130 A
2,6 KVA
4,3 KVA
11,3 A
18,6 A
230 VAC
50÷60 Hz
0.99
0.85
5 – 140 A
80 V
120 A
150 A
3.9 KVA
5,1 KVA
16,9 A
22,2 A
Tab. 05
Duty cycle 40%
Main voltage
Frequency
Cos φ
Efficiency
Current range
Off load voltage
Output current 60%
Output current 35%
Absorbed power 60%
Absorbed power 40%
Main current 60%
Main current 40%
Tab. 06/A
Duty cycle 60%
Main voltage
Frequency
Cos φ
Efficiency
Current range
Off load voltage
Output current 100%
Output current 60%
Absorbed power 100%
Absorbed power 60%
Main current 100%
Main current 60%
230 VAC
50/60 Hz
0.99
0.85
5 – 130 A
80 V
85 A
130 A
2,6 KVA
4.3 KVA
11,3 A
18,6 A
230 VAC
50/60 Hz
0.99
0.85
5 – 160 A
80 V
120 A
160 A
3.9 KVA
5,5 KVA
16,9 A
24 A
Tab. 06/B
Duty cycle 60% - 3 Ph
Main voltage
Frequency
Cos φ
Efficiency
Current range
Off load voltage
Output current 100%
Output current 60%
Absorbed power 100%
Absorbed power 60%
Main current 100%
Main current 60%
230VAC
50/60 Hz
0.99
0.85
5 – 160 A
90 V
120 A
140 A
4,3 KVA
4,7 KVA
18,6 A
20,4 A
230 VAC
50/60 Hz
0.99
0.85
5 – 150 A
80 V
120 A
150 A
3.9 KVA
5,1 KVA
16,9 A
22,2 A
230 VAC
50/60 Hz
0.99
0.85
1 – 140 A
60 V
110 A
140 A
3.5 KVA
4.7 KVA
17 A
22.7 A
400 VAC
50/60 Hz
0.99
0.85
5 – 220 A
60 V
190 A
220 A
6,8 KVA
8,3 KVA
9,9 A
12 A
230 VAC
50/60 Hz
0.99
0.85
5 – 160 A
80 V
140 A
160 A
4,6 KVA
5.5 KVA
20,3 A
24 A
230 VAC
50/60 Hz
0.99
0.85
1 – 160 A
60 V
130 A
160 A
4.2 KVA
5.5 KVA
20 A
26 A
400 VAC
50/60 Hz
0.99
0.85
5 – 270 A
60 V
220 A
270 A
8,3 KVA
10,9 KVA
12 A
15,7 A
230 VAC
50/60 Hz
0.99
0.85
5 – 180 A
80 V
150 A
180 A
5.1 KVA
6.4 KVA
22,2
27,8 A
230 VAC
50/60 Hz
0.99
0.85
1 – 180 A
60 V
140 A
180 A
4.9 KVA
6.2 KVA
25 A
28 A
230 VAC
50/60 Hz
0.99
0,85
1 – 200 A
60 V
160 A
200 A
5.5 KVA
7.3 KVA
24 A
31 A
400 VAC
50/60 Hz
0.99
0.85
5 – 330 A
60 V
220 A
330 A
8,3 KVA
14,3 KVA
12 A
20,7 A
15
Tab. 07
Duty cycle 70%
Main voltage
Frequency
Cos φ
Efficiency
Current range
Off load voltage
Output current 100%
Output current 70%
Absorbed power 100%
Absorbed power 70%
Main current 100%
Main current 70%
Tab. 08
TIG
Duty Cycle
Main voltage
Frequency
Cos φ
Efficiency
Current range
Off load voltage
Output current 40%
Output current 60%
Output current 100%
Absorbed power 40%
Absorbed power 60%
Absorbed power 100%
Main current 40%
Main current 60%
Main current 100%
Fig. 01
16
mma
60% -160 A
230 VAC
50/60 Hz
0.99
0.85
5 – 160 A
80 V
160 A
130 A
5.5 KVA
4,3 KVA
24 A
16,9 A
230 VAC
50/60 Hz
0.99
0.85
5 – 160 A
60 V
140 A
160 A
4,7 KVA
5.5 KVA
20,3 A
24 A
tig
3,4 KVA
2,6 KVA
14,9 A
11,3 A
230 VAC
50/60 Hz
0.99
0.85
5 – 180 A
60 V
150 A
180 A
5,1 KVA
6,4 KVA
22,2 A
27,8 A
mma
40% - 200 A
230 VAC
50/60 Hz
0.99
0.85
5 – 200 A
60 V
200 A
160 A
140 A
7,3 KVA
5,5 KVA
4,7 KVA
31,9 A
24 A
10,4 A
tig
4,7 KVA
3,4 KVA
2,9 KVA
20,5 A
14,9 A
12,5 A
230 VAC
50/60 Hz
0.99
0.85
5 – 200 A
60 V
170 A
200 A
6 KVA
7,3 KVA
25,9 A
31,8 A
mma
40% - 250 A
400 VAC
50/60 Hz
0.99
0.85
5 - 250 A
80 V
250 A
210 A
180 A
9,8 KVA
7,8 KVA
6,4 KVA
14,2 A
11,3 A
9,3 A
tig
6,5 KVA
5,1 KVA
4,1 KVA
9,5 A
7,3 A
5,9 A
DICHIARAZIONE DI CONFORMITA’
DECLARATION OF CONFORMITY
DECLARACION DE CONFORMIDAD
KONFORMITATSERKLARUNG
DECLARATION DE CONFORMITE’
Si dichiara che l’apparecchio tipo / We hereby state than the machine type /
On déclare que la machine type / Die Maschine von Typ /
se declara que el aparato tipo / Declara se que a màquina tipo
E’ conforme alle direttive / Is in compliance with the directives / entspricht den Richtlinien /
est conforme aux directives / es conforme a las directivas / é conforme as directivas
2009/95/CEE REQUISITI APPARECCHI BASSA TENSIONE
2004/108/CEE COMPATIBILITA’ ELETTROMAGNETICA
2006/42/CEE REQUISITI ESSENZIALI DI SICUREZZA
Verifiche e prove eseguite conformemente alle norme:
EN 60974-1 ed. 07/01
EN 60974-7 ed. 11/00
EN 60974-10 ed. 11/03
Albissola Marina, 04/02/2014
Viva Elettronica!
Viva Elettronica!
Amministratore Unico
17
Viva Elettronica! s.r.l.
Via delle Industrie 218/a, 17012 Albissola Marina (SV)
Tel. 019 7701389 - www.eps-inverter.com - [email protected]
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