EWM inverter STICK 350 CEL KLR Operating Instructions Manual

EWM HIGHTEC WELDING GmbH

Dr.-Günter - Henle - Straße 8; D-56271 Mündersbach

Phone: +49 (0)2680.181-0; Fax: +49 (0)2680.181-244

Internet:

www.ewm.de

; E-mail:

[email protected]

GB

Operating instructions

Inverter

STICK Welding Machines from 250A to 350A, portable

inverter

STICK 250 H-2

inverter

STICK 350 CEL

inverter

STICK 350 CEL KLR

inverter

STICK 350 CEL PWS

ã

2002

These operating instructions must be read before commissioning.

Failure to do so may be dangerous.

Machine may only be operated by personnel familiar with the appropriate safety regulations.

The machines bear the conformity mark and thus comply with the

•

EC Low Voltage Directive (73/23/EEC)

•

EC EMC Directive (89/336/EEC)

Geräte können entsprechend IEC 60974, EN 60974, VDE 0544 in Umgebung mit erhöhter elektrischer Gefährdung eingesetzt werden.

Subject to alteration.

Item No.: 099-002029-EWM01 Version: 07.08.02

EG - Konformitätserklärung

EU - conformity declaration

Déclaration de Conformité de U.E.

Name des Herstellers:

Name of manufacturer:

Nom du fabricant:

EWM HIGHTEC WELDING GmbH

(nachfolgend EWM genannt)

(In the following called EWM)

(nommé par la suite EWM)

Originaldokument

Address of manufacturer:

Dr.- Günter - Henle - Straße 8

D - 56271 Mündersbach – Germany

Hiermit erklären wir, daß das

[email protected]

Adresse du fabricant:

liegt jedem Gerät bei!

nachstehend bezeichnete Gerät in

We herewith declare that the machine described below meets the standard safety

Par la présente, nous déclarons que la conception et la construction ainsi que le regulations of the EU- guidelines mentionned below in its conception and modèle, mis sur le marché par nous, de l´appareil décrit ci - dessous

seiner Konzeption und Bauart sowie in der von uns in Verkehr gebrachten

Ausführung den grundlegenden

Sicherheits-anforderungen der unten genannten EG- Richtlinien entspricht.

Im Falle von unbefugten

Veränderungen, unsachgemäßen

Reparaturen und / oder unerlaubten

Umbauten, die nicht ausdrücklich von

EWM autorisiert sind, verliert diese

Erklärung ihre Gültigkeit.

construction, as well as in the design put into circulation by us. In case of unauthorized changes, improper repairs and / or unauthorized modifications, which have not been expressly allowed by EWM, this declaration will lose its validity.

correspondent aux directives fondamentales de sécurité de la U.E.

mentionnées ci- dessous. En cas de changements non autorisés, de déclaration devient caduque.

h mac hine!

autorisés expressément par EWM, cette

Gerätebezeichnung:

Original document

Déscription de la machine:

Gerätetyp:

Type of machine:

Type de machine:

is enc losed with eac

Article number:

Numéro d´article

Seriennummer:

Serial number:

Numéro de série:

Optionen:

Options:

Options:

keine

none aucune

hine!

Zutreffende EG - Richtlinien: EG - Niederspannungsrichtlinie (73/23/EWG)

Applicable EU - guidelines: EU - low voltage guideline

Document original

EG- EMV- Richtlinie (89/336/EWG)

EU- EMC guideline

U.E.- EMC directive

Angewandte harmonisierte Normen:

est joint à toute mac

Normes harmonisées appliquées:

EN 60974 / IEC 60974 / VDE 0544

EN 50199 / VDE 0544 Teil 206

Hersteller - Unterschrift:

Signature of manufacturer:

Signature du fabricant:

Michael Szczesny , Geschäftsführer

managing director gérant

05.2000

Table of contents

Page

4

5

Safety instructions.............................................................................................................................. S/1

For your safety............................................................................................................................ S/1

Transport and Installation ........................................................................................................... S/3

Ambient conditions ..................................................................................................................... S/3

Notes on the use of these operating instructions ....................................................................... S/3

1 Technical data........................................................................................................................... 1/1

1.1

Area of application............................................................................................................ 1/1

2 Description of the machine ..................................................................................................... 2/1

3

6

Function specification for logic control................................................................................. 3/1

3.1

Logic control ..................................................................................................................... 3/1

3.2

Function sequence for MMA welding ............................................................................... 3/2

3.3

Remote control ................................................................................................................. 3/3

Quick start – the fastest way to weld ..................................................................................... 4/1

Commissioning......................................................................................................................... 5/1

5.1

Area of application............................................................................................................ 5/1

5.1.1 Proper usage.......................................................................................................... 5/1

5.2

Setting up the welding machine ....................................................................................... 5/1

5.3

Mains connection ............................................................................................................. 5/1

5.4

Welding machine cooling system..................................................................................... 5/1

5.5

Workpiece lead................................................................................................................. 5/1

5.6

Electrode holder ............................................................................................................... 5/1

Maintenance and care .............................................................................................................. 6/1

7

8

Operating problems, causes and remedies........................................................................... 7/1

7.1

Customer checklist ........................................................................................................... 7/1

Spare parts list.......................................................................................................................... 8/1

8.1

Front view ......................................................................................................................... 8/1

8.2

Rear view ......................................................................................................................... 8/2

8.3

inverter

STICK 250H-2 ........................................................................................................... 8/3

8.4

8.3.1 Right-hand side ...................................................................................................... 8/3

8.3.2 From above ............................................................................................................ 8/3

8.3.3 Left-hand side ........................................................................................................ 8/4 inverter

STICK 350 / 350CEL / 350CEL PWS ....................................................................... 8/5

8.4.1 Right-hand side ...................................................................................................... 8/5

8.4.2 From above ............................................................................................................ 8/6

8.4.3 Left-hand side ........................................................................................................ 8/6

9 Accessories, options ............................................................................................................... 9/1

9.1

Remote control ................................................................................................................. 9/1

9.1.1 STICK 250 H-2 / 350 CEL / 350 CEL / 350 CEL KLR / 350 CEL PWS ................. 9/1

9.1.2 STICK 350 CEL PWS ............................................................................................ 9/1

9.2

General accessories......................................................................................................... 9/1

9.2.1 STICK 250 H-2....................................................................................................... 9/1

9.2.2 STICK 350 CEL / 350 CEL / 350 CEL KLR / 350 CEL PWS................................. 9/1

10 Circuit diagrams ..................................................................................................................... 10/1

10.1 STICK 250 H-2 ............................................................................................................... 10/1

10.2 STICK 350 CEL.............................................................................................................. 10/2

10.3 STICK 350 CEL KLR...................................................................................................... 10/3

10.4 STICK 350 CEL PWS..................................................................................................... 10/4

Contents/1

Safety instructions

For Your Safety:

Ignoring the following safety precautions can be fatal.

Observe accident prevention regulations.

Designed use

This machine is manufactured according to the current state of the art and current regulations and standards. It is to be operated only for the designed use (see Chap. Commissioning/Area of application).

Use not as designed

This machine may be a hazard to persons, animals and property, however, if it is

· not used as designed

· used by unskilled persons who have not been trained,

· modified or converted improperly

Our operating instructions will provide you with an introduction into the safe use of the machine.

Therefore please read them closely and only start work when you are familiar with them.

Any person involved in operation, maintenance and repair of this machine must read and follow these operating instructions, especially the safety precautions. Where appropriate, this must be confirmed by signature.

Furthermore, the

· relevant accident prevention regulations,

· generally recognized safety regulations,

· regionally specific provisions etc. are to be adhered to.

Electric shocks can be fatal

·

The machine may only be connected to correctly earthed sockets.

·

Only operate with intact connection lead including protective conductor and safety plug.

·

An improperly repaired plug or damaged mains cable insulation can cause electric shocks.

·

The machine may only be opened by qualified and authorised personnel.

·

Before opening, pull out the mains plug. Switching off is not sufficient. Wait for 2 minutes until capacitors are discharged.

·

Always put down welding torch, stick electrode holder in an insulated condition.

·

The machine must not be used to defrost pipes.

Even touching low voltages can cause you to jump and lead to accidents, so:

·

Safeguard yourself against falls, e.g. from a platform or scaffolding.

·

When welding, operate earth tongs, torch and workpiece properly, not in ways for which they are not intended. Do not touch live parts with bare skin.

·

Only replace electrodes when wearing dry gloves.

·

Never use torches or earth cables with damaged insulation.

S/1


Smoke and gases can lead to breathing difficulties and poisoning.

·

Do not breathe in smoke and gases.

·

Ensure that there is sufficient fresh air.

·

Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarbon fumes can be converted into poisonous phosgene by ultraviolet radiation.

Workpiece, flying sparks and droplets are hot

·

Keep children and animals well away from the working area. Their behaviour is unpredictable.

·

Move containers with inflammable or exposive liquids away from the working area.

There is a danger of fire and explosion.

·

Never heat explosive liquids, dusts or gases by welding or cutting. There is also a danger of explosion if apparently harmless substances in closed containers are able to build up excess pressure when they are heated.

Take care to avoid fire hazards

·

Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying, when parts are glowing or hot slag is present.

·

A constant check must be kept on whether fire hazards have been created in the working area.

·

Highly inflammable objects, such as matches and cigarette lighters for example, must not be carried in trouser pockets.

·

You must ensure that fire extinguishing equipment - appropriate to the welding process

- is available close to the welding work area and that easy access is possible.

·

Containers in which fuels or lubricants have been present must be thoroughly cleaned before welding begins. It is not sufficient simply for the receptacle to be empty.

·

After a workpiece has been welded, it must only be touched or brought into contact with inflammable material when it has cooled down sufficiently.

·

Loose welding connections can completely destroy protective conductor systems of interior installations and cause fires. Before beginning welding work, ensure that the earth tongs are properly fixed to the workpiece or welding bench and that there is a direct electrical connection from the workpiece to the power source.

Noise exceeding 70 dBA can cause permanent hearing damage

·

Wear suitable earmuffs or plugs.

·

Ensure that other people who spend time in the working area are not inconvenienced by the noise.

Secure gas cylinder

·

Place shielding gas cylinders in the holders provided for them and secure with safety chains.

·

Take care when handling cylinders; do not throw or heat, guard against them toppling over.

·

When moving by crane, take off the gas cylinder from the welding machine.

S/2


Interference by electrical and electromagnetic fields is possible e.g. from the welding machine or from the high-voltage pulses of the ignition unit.

·

As laid down in Electromagnetic Compatibility Standard EN 50199, the machines are intended for use in industrial areas; if they are operated e.g. in residential environments problems can occur in ensuring electromagnetic compatibility.

·

The functioning of heart pacemakers can be adversely affected when you are standing near the welding machine.

·

Malfunctioning of electronic equipment (e.g. EDP, CNC equipment) in the vicinity of the welding location is possible.

·

Other mains supply leads, trip leads, signal and telecommunications leads above, under and near the welding device may be subject to interference.

Electromagnetic interference must be reduced to such a level that it no longer constitutes interference. Possible reduction measures:

·

Welding machines should be regularly maintained (see Sect. “Maintenance and care”)

·

Welding leads should be as short as possible and run closely together on or near to the ground.

·

Selective shielding of other leads and equipment in the environment can reduce radiation.

Repairs and modifications may only be carried out by authorised, trained, specialist personnel. The warranty becomes null and void in the event of unauthorised interference.

Our operating instructions will provide you with an introduction into the safe use of the machine.

Therefore please read them closely and only start work when you are familiar with them.

S/3


Transport and set-up

Machines may only be moved and operated in an upright position.

Before moving, pull out mains plug and place on the machine.

Secure high-pressure shielding gas cylinder with safety chain to prevent it from toppling over.

When setting up the machine, tilt resistance is only guaranteed up to an angle of 15°

(as specified in EN 60974).

Environmental conditions:

The welding machine can be operated in a location where there is no risk of explosion at

· an ambient temperature

· a relative air humidity of -10°C (plasma machines 0°C) to +40°C and up to 50% at 40°C.

· where the surrounding air is free of unusual amounts of dust, acids, corrosive gases or substances etc., insofar as they do not occur during welding.

Examples of unusual operating conditions:

Unusual corrosive smoke, vapour, excessive oil vapour, unusual vibrations or jolts, excessive quantities of dust such as grinding dust etc., severe weather conditions, unusual conditions near the coast or on board ship.

·

When setting up the machine, ensure that air inlets and outlets are unobstructed.

The machine is tested to Protection Standard IP23, i.e.:

·

Protection against penetration of solid foreign bodies

Æ

> 12mm,

·

Protection against water spray up to an angle of 60° to the vertical.

Notes on the use of these operating instructions

These operating instructions are arranged in Sections.

To help you find your way around more quickly, in the margins you will occasionally see, in addition to sub-headings, icons referring to particularly important passages of text which are graded as follows depending on their importance:

(Note): Applies to special technical characteristics which the user must note.

(Warning): Applies to working and operating procedures which must be followed precisely to avoid damaging or destroying the machine.

(Caution): Applies to working and operating procedures which must be followed precisely to avoid endangering people and includes the “Warning” symbol.

Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet points, e.g.:

·

Insert plug of welding current lead into socket (Sect. 5, G2) and lock.

Meaning of the diagram descriptions: e.g. (C1) means: Item C / Figure 1 in the respective Section e.g. (Sect. 3, C1) means: in Section 3 Item C / Figure 1

S/4

1 Technical data

Inverter

Welding current

Welding voltage

Max. welding voltage

Duty cycle (40ºC)

Max. welding current at

30%DC

60%DC

100%DC

Load alternation

Open circuit voltage

Mains voltage (tolerances)

STICK 250 H-2

5A - 250A

20.2V -30V

40V

STICK 350 CEL STICK350CELPWS

20A - 350A

20.2V -34V

60V

350A

250A

190A

10min (60% DC

∧

6 min welding, 4min break)

106V 92V

3 x 400V (+20% to -25%)

3 x 415V (+15% to -25%)

50 / 60Hz

Mains frequency

Mains fuse, safety fuse - slow-blow

Mains connection lead

Max. connected power

3 x 16A

H07RN-F4G1.5

10.5kVA

3 x 25A

H07RN-F4G2.5

17.8kVA

Recommended generator rating cos

ϕϕϕϕ

at I max

Efficiency

14kVA

89%

0.99

23.7kVA

91%

Insulation class

Protection classification

Ambient temperature

Machine cooling

Workpiece lead

≤≤≤≤

5m

Total weight

35mm

26kg

2

H

IP 23

-10

°

C to +40

°

C fan

35.5kg

50mm

2

37.5kg

Dimensions (LxWxH) incl.

handle

540x230x460mm

Constructed to (standards)

IEC 60974 / EN 60974 / VDE 0544

EN 50199 / VDE 0544 Teil 206

/

690x230x460mm

1/1

2 Description of the machine

A1

B1

F1

G1

E1

F1

G1

H1

I1

C1

D1

E1

Fig. 1: Front view of

Inverter

STICK 350 CEL PWS

Item Symbol Description

A1

B1

0

1

Carrying handle

Main switch

H1

I1

C1

D1

Position means : negative welding voltage potential (

-

) at welding current socket positive welding voltage potential (

+

) at welding current socket

Position means : positive welding voltage potential ( + ) at welding current socket negative welding voltage potential (

-

) at welding current socket

It is only possible to change the polarity when no welding current is flowing.

Welding current socket +

+ Positive polarity at pole changeover switch position

PWS)

(STICK 350 CEL

– Negative polarity at pole changeover switch position

PWS)

(STICK 350 CEL

Cableless remote control changeover switch “ON/OFF” (STICK 350 CEL KLR)

Logic control (see chap. 3)

Fuse (at the rear of the machine)

Remote control connection

Welding current socket -

- Positive polarity at pole changeover switch position

PWS)

+ Negative polarity at pole changeover switch position

PWS)

(STICK 350 CEL

(STICK 350 CEL

2/1

3 Function specification

3.1

Logic control

A1

D1

B1 E1

C1

Fig. 1: Logic control

Item Symbol Description

A1

B1

Hotstart current

Hotstart current IHot infinitely adjustable from the minimum to the maximum welding current.

The hotstart device makes it possible to ignite and re-ignite critical stick electrodes easily.

Adjustable arcforcing

Shortly before the electrode threatens to stick, the arcforcing device sets an increased current designed to prevent the electrode from sticking. The value of the increase in current depends on the welding voltage and the setting on the arcforcing potentiometer.

Excellent welding properties are achieved with all difficult electrodes thanks to the adjustable arcforcing.

( U/V )

"Far left" position:

Minimal arcforcing

Þ

gentle arc, slight increase in current before short-circuit.

Used with rutile, coated stick electrodes.

"Centre" position:

Moderate arcforcing

Þ

normal arc, moderate increase in current before shortcircuit.

Used with basic, coated stick electrodes.

( I/A)

C1

D1

E1

"Far right" position:

Strong arcforcing

Þ

hard arc, great increase in current before short-circuit.

Used with cellulose stick electrodes.

Hotstart time

Hotstart time t

Hot

infinitely adjustable from 0 sec. - 2 sec.

The hotstart device ensures that critical stick electrodes can be ignited and reignited easily. The hotstart current and time can also be adjusted externally using the FR 35 remote control.

Yellow LED ( excess temperature )

Thermal monitors in the power unit shut down at excess temperature and the excess temperature indicator lamp comes on. After cooling, welding can proceed without any further measures.

Main current I

1

(welding current)The welding current I

1

can be infinitely adjusted from the minimum to the maximum welding current.

3/1


3.2

Antistick

If the stick electrode sticks despite the arcforcing device, the machine automatically switches over to the minimum current within about 1 second to prevent the electrode overheating. If the antistick device has been triggered, check the welding current setting and correct if necessary.

3.3

Functional sequence for MMA welding

I

I

Hot

Hotstart-Strom

I

1

Hauptstrom

Hotstart-Zeit t

Fig. 2 Stick electrode flow chart – welding with hotstart device

•

Strike the stick electrode on the workpiece.

•

The stick electrode ignites the arc at the set hotstart current I

Hot

and welds with this current until the hotstart time t

Hot

elapses.

•

The hotstart current drops to the set main current I

1

and remains constant until the end of the welding process (see flow chart)

•

If the stick electrode sticks in the welding pool for longer than 1 second, the antistick device comes into force and the welding current is reduced to the minimum current. Check the welding current setting and correct as necessary according to the manufacturer's instructions.

3/2


3.4

Remote control

Only the remote controls described in these operating instructions should be connected!

Plug the remote control into the remote control socket (chap. 2, H1) and lock it only when the machine is switched off.

The remote control is detected automatically when the welding machine is switched on.

See the operating instructions for the remote control for more detailed information.

FR 21 footoperated remote control

Functions

•

The welding current I

1

can be set to any value from the minimum to the maximum current regardless of the welding current selected on the machine.

FR 30 manual remote control

Functions

•


1


FR 30F manual remote control

Functions

•


1


In this process, the welding current I

1

can be adjusted in 2 ranges (coarse/fine adjustment).

Commissioning:

•

Features

•

Large adjusting knob

FR 30 PWS manual remote control

Functions

•

Pole changeover switch for changing the welding polarity.


1


Commissioning:

•

The pole changeover switch on the welding machine must be in position +.

FR 30F PWS manual remote control

Functions

•

Pole changeover switch for changing the welding polarity.


1


In this process, the welding current I

1 adjustment).

can be adjusted in 2 ranges (coarse/fine

Commissioning:

•

The pole changeover switch on the welding machine must be in position +.

Features

•

Large adjusting knob, 2 setting ranges

3/3


FR 30 KL cableless manual remote control

Functions

•


1


Commissioning:

•

The changeover switch on the welding machine must be in the ON position

(cableless remote control active)

Features

•

Welding current adjustment without connecting cables (the welding machine must be equipped accordingly for operation).

FRA 40 manual remote control

Functions

•


1


•

The machine can be switched from FRA 40 remote control (switch position up) to another remote control (switch position down) with the changeover switch.

Commissioning:

•

Adjust the measurement range of the welding current display to the maximum current of the machine.

(DIP switch in the remote control, setting on delivery: 250A)

Features

•

LED welding current display.

•

10-turn helical potentiometer for accurate setting of the welding current.

•

Connection facility for further remote controls.

Hotstart FR 35 manual remote control

Functions

•

Remote control “ON/OFF” (changeover switch on the remote control).

•

Hotstart current and hotstart time infinitely adjustable.

•


1

is adjustable to any value from the minimum to the maximum current regardless of the welding current selected on the machine.

Commissioning:

•


1


•

Switch on the remote control.

Features

•

Connection facility for the FRA 40 remote control.

When the FR35 is in use, the hotstart current and time must be set to their minimum values on the welding machine.

3/4

4 Quick start – the shortest way to welding

(observe safety instructions)

+

Preparations

•

Plug in the mains plug.

(Remember fuse!)

•

Insert workpiece lead, lock and attach to conduct to the workpiece.

•

Connect electrode holder

•

Plug in the remote control connector plug

0

1

•

Switch on machine.

Setting

•

Set welding current I

1

.

•

Set arcforcing.

•

Preselect polarity with the pole changeover switch (PWS machines only).

•

Set hotstart current.

•

Set hotstart time.

Fault elimination

Poor welding properties

•

Incorrect polarity setting on the pole changeover switch.

Excess temperature LED is on:

•

Duty cycle exceeded > allow machine to cool

4/1

5 Commissioning

5 Commissioning

5.1

Area of application

The machines are used exclusively for stick electrode direct current welding.

5.1.1

Proper usage

These welding machines are suitable only for MMA direct current welding for rutile, basic and cellulose electrodes.

Any other use is regarded as "improper" and no liability is assumed for any damage arising therefrom.

We can only guarantee smooth and trouble-free operation of the machines when used in conjunction with the cooling units, welding torches and accessories from our range!

5.2

Setting up the welding machine

Follow the safety instructions on the opening pages entitled "For Your Safety".

•

Set up the machine so that there is sufficient space to adjust the operating elements.

•

Ensure that the machine is set up in a stable position and is appropriately secured.

5.3

Mains connection

The correct mains plug must be attached to the mains supply lead on the machine. The connection must be made by an electrician in compliance with current VDE regulations.

Any phase sequence can be used!

The operating voltage shown on the rating plate must match the mains voltage! For mains fuse protection, please refer to the “Technical data” chapter.

•

Insert mains plug into the appropriate socket when the machine is switched off.

5.4

Welding machine cooling system

Observe the following to attain the optimum duty cycle of the power units:

•

Ensure that the working area is adequately ventilated,

•

Do not obstruct the air inlets and outlets on the machine,

•

No metal parts, dust or other foreign bodies are permitted to enter the machine.

5.5

Workpiece lead

Remove paint, rust and dirt from clamping and welding areas with a wire brush. Attach the workpiece collet or clamp directly next to the welding position. Structural parts, pipes, rails etc. may not be used as return leads for the welding current unless these parts are the actual workpieces.

A perfect current connection must be ensured for welding benches and appliances.

•

Insert cable plug on the workpiece lead into the welding current socket (chap. 2, E1 or I1 depending on the polarity of the electrode

)

and lock by turning to the right.

MMA welding:

The polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

5.6

Electrode holder connection

•

Insert cable plug of the stick electrode holder into the “+” welding current socket (chap. 2, E1

and I1 depending on the polarity and electrode

)

and lock by turning to the right.

The polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

(+ Positive polarity at pole changeover switch position

(- Negative polarity at pole changeover switch position

, STICK 350 CEL PWS only)

, STICK 350 CEL PWS only)

5/1

6 Maintenance and care

Under normal operating conditions, these welding machines are largely maintenance-free and

D require a minimum of care. However, a number of points should be observed to guarantee the

6

.

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grundle

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Cleaning

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9-000GAR-EWMxx.

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The instructions, guidelines and standards given in

The individual components should be handled as follows:

• been completely re

The releva

6.2

F

•

"Gener nt instru vised and are theref al notes on the 3 ye

, guidelines an ore no longer valid!

Not observing

ar war ranty", d standards can be f

Repetition test according to VDE 0702, VBG 4 and VGB 15

9-000GAR-EWMxx.

tions can be potentially fat instructions. If required, a copy can be requested from us.

ound in the enclosed supplements e r authorised sp

It is recommended to conduct quarterly checks and an annual check. The annual check should also be carried out after every repair. Test sequence:

Les consignes, dire mises à jour et ne sont donc plus v

•

Visual check for correct condition généra

al!

ecialist

dealer!

•

et norm es indiquées au chapitre « Maintenance et entretien » ont été

Si vou

Annual check:

• revendeur autorisé

Visual check for correct condition alable s !

!

t normes

•

Measurement of protective conductor resistance

•

, vous

pouv bles d

Measurement of insulation resistance following internal cleaning of the welding power source

•

Measurement of open circuit voltage ez vo us les procurer auprès de vo

•

Functional test of the welding machine

6.2.1

I

Visual check for correct condition

mort !

tre

Le istruz

• genera ioni, direttive

Se i documenti non f

e per questo motivo

e norme

•

•

•

•

Defects in anti-kink protection and the strain relief of the connection lead, mains switch.

L'inosservan

ossero disponibili, possono

Signs of overload and improper use.

Damage to stop points and casing.

enzion

099-000GAR-EWMxx.

essere richiest

!

e e cur a” so no state ento qui allegato “Is

•

Non-permitted interference and modifications.

i al rive

pericolo di vita!

•

The type plate and warning symbol must be present and legible.

truzioni nditore autorizz ato!

6.2.2

Measurement of protective conductor resistance

Measure between safety contact of the mains plug and exposed, touchable metal parts, e.g. casing screws. During measuring, the machine connection cable must be moved along the entire length, especially near the connection points.

The resistance should be < 0.1

Ω

Measurement should be carried out with a minimum of 200 mA.

6/1

6 Maintenance and care

6.2.3

Measurement of insulation resistance

Disconnect the machine from the mains. Remove the mains plug!

Open the machine and clean carefully (as described above).

Switch on mains switch.

•

Insulation resistance mains current circuit-casing


a) Step switch controlled machines:

The machine must be opened. Measure the insulation resistance from the main fuse input and mains fuse output to the casing. At the mains fuse input it is necessary to measure from each connection, at the mains fuse output only from one connection.

The resistance must be > 2.5 M

Ω

.

b) Inverter machines:

Measure from one phase of the mains plug to the housing.

The resistance should be > 2.5 M

Ω

.

•

Insulation resistance welding current circuit-casing

Measure between a welding socket and protective conductor.

The resistance should be > 2.5 M

Ω

.

•

Insulation resistance mains current circuit welding-current circuit


a) Step switch controlled machines:

Measure the insulation resistance between the mains fuse output and a welding current socket.

The resistance must be > 5 M

Ω

.

b) Inverter machines:

Measure between a phase of the mains plug and a welding current socket.

The resistance must be > 5.0 M

Ω

.

6.2.4

Measurement of open circuit voltage

(according to EN 60974-1 / VDE 0544 T1)

Diode similar 1N 4007

1k0

+

Input

0k2

0...5k

10nF

6u8F

V

Connect the measuring circuit to the welding current sockets as shown in fig. 1.

The voltmeter should show the mean value.

Adjust the potentiometer from 0k

Ω

to 5k

Ω during the measurement.

The measured voltage must not deviate from that specified on the rating plate (U

0

) by more than 10% and must be no higher than 113V.

-

Measurement circuit for peak values

6.2.5

Functional test of the welding machine

Conduct a functional test depending on the type of machine.

6

.

3 Repair work

Repair and maintenance work may only be performed by trained specialist staff.

In 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 original spare parts.

When ordering spare parts, the machine type, serial number and item number of the machine, as well as the type description and item number of the spare part must be quoted.

If repair or maintenance work is carried out on this machine by personnel who are not trained and authorised to undertake such work, the right to claim under the warranty becomes void.

6/2

7 Operating faults, causes and remedies

7 Operating faults, causes and remedies

All machines are subjected to strict manufacturing and final inspection procedures. If, despite this, something fails to work at any time, please check machine using the following process chart. If none of the fault elimination procedures described results in the correct functioning of the machine, please contact your authorised dealer.

7.1

Customer checklist

Machine switched on

yes

Machine is operative

(fan running)

No

•

Mains supply interrupted

•

Mains plug not inserted

•

Mains fuse faulty

•

Mains power switch faulty

•

Mains plug wrongly connected yes

Welding current

No

•

Electrode holder not connected

•

Workpiece lead not connected yes

Good welding properties

No

•

Wrong material composition

•

Electrodes and workpiece leads misconnected

(follow manufacturer’s instructions for electrodes)

•

Electrode not clean

•

Incorrect switch setting PWS +/yes

Remote control functions

No

•

Remote control plug not inserted in the machine

•

Remote control or cable defective

8/1

8 Ersatzteilliste / Spare Parts List


8.1

Vorderseite / front side

Pos.

1

2

3

4

5

6

7

8

9

Bezeichnung

Halterung für Griffstange

Griffstange

Hauptschalter EIN/AUS

Schalter Switch

Kippschalter

Schweißstrombuchse

Gummifüsse

Anschlußbuchse 14-polig

EB3

Drehknopf

∅

23mm

Deckel für Drehknopf

∅

23mm

Pfeilscheibe für Drehknopf

∅

23mm

Drehknopf

∅

31mm

Deckel für Drehknopf

∅

31mm

Pfeilscheibe für Drehknopf

∅

31mm

PCB Steuerelektronik

STICK1/3

Knob

Abb. / picture 1

Description

Holder for hand grip

Hand grip

Mains switch ON/OFF knob griff

Toggle switch

Welding current socket outlet

Rubber feet

Connection socket 14pole

Cover for knob

Arrow indicator for knob

Knob

Cover for knob

Arrow indicator for knob

PCB control

inverter

STICK 250H-2 inverter

STICK 350

074-000237-00000

074-000237-00005 074-000237-00013

074-000279-00000

094-001814-00000

094-001898-00000

074-000232-00000

094-002876-00000

040-000408-00000

074-000315-00000

074-000315-00001

074-000315-00002

074-000234-00000

074-000234-00001

074-000234-00002

040-000415-00000

9/1


8.2

Rückseite / rear view


Pos.

Bezeichnung

10

Kabelverschraubung

Description

Cable gland

Kabelverschraubung Mutter Cable gland nut

11

12

13

Netzkabel

Gehäusedeckel

Sicherungshalter mit Mutter

(nur PWS)

Sicherungskappe

(nur PWS)

Sicherung

(nur PWS)

Mains cable

Housing cover

Fuse holder with nut

(only PWS)

Fuse cap

(only PWS)

0,5AT Fuse

(only PWS)

inverter

STICK 250H-2 inverter

STICK 350

094-003293-00000

024-000205-00001

092-000661-00000 092-000662-00000

094-002817-00002 094-002744-00003

094-000001-00000

-

-

094-000001-00001

094-000202-00000

9/2


8.3

inverter

STICK 250H-2

8.3.1

Rechte Seite / right side

14

Pos.

Bezeichnung:

1

2

3

4

14

Leiterplatte Schutzbeschaltung

PCB Schweißelektronik

PCB Inverter Steuersatz

Sek. Diodenkühler



Diodenmodul (3xbestückt)

Lüfter

8.3.2

Von oben / from the top

4 3 2 1


Description:

PCB contactor switching

PCB welding electronic

PCB inverter control stack

Sec. diode cooler



PCB for the driver electronics

Fan

STICK 250H-2

040-000531-00000

040-000470-00001

040-000290-00022

072-000154-00000

040-000495-00000

040-000531-00000

080-000257-00004

074-000267-00000

13

5

Pos.

Bezeichnung

5

6

PCB Treiberelektronik TRI4

Inverter Steuersatz Primärseite

DW7,5/380/1

7

13

Leiterplatte Sperrwandler

SPW2/380V/1

Netzfilter NEF2

6 7


Description

PCB for the drive electronics

Inverter control stake primary side

Primary control PCB

Mains filter

STICK 250H-2

040-000503-00000

040-000303-00000

040-000289-00000

040-000505-00000

9/3


8.3.3

Linke Seite / left side

12

11

10 9 8

Pos.

Bezeichnung

8

9

10

11

12

Primärschalter Minus INV50/1000.6M

Primärschalter Plus INV50/1000.6P

Varistor Schutzbeschaltung für

Netzgleichrichter SB460/6

Thyristor Dioden Modul MTD55-14A

Netzgleichrichter B6 75/16


Description

Primary switch

Primary switch

Varistor modules, protective circuit for mains rectifier

Thyristor diodes module

Mains rectifier

STICK 250H-2

080-000294-00000

080-000295-00000

072-000292-00000

064-000083-00014

080-000204-00016

9/4


8.4

inverter

STICK 350 / 350CEL / 350CEL PWS

8.4.1

Rechte Seite / right side

17

16

3

4

16

17

Pos.

1

2

4

3 2

1

Bezeichnung


DSB3/4.1

Sekundär Diodenkühler

SDK6XMDDM 121-04 F02-01/1


VAR1/1


DSB3/4.1


DSB1/2

Diodenmodul (6x)

PCB Schweißelektronik FAL1/AF/1

PCB Inverter Steuersatz

TRDC2/300/3

Steuerelektronik für Handregler HDR-

Q1 (optional) FST-Q1

Lüfter


Description


Secondary diode cooler



PCB contactor switching diode modules (6x)

PCB welding electronics

PCB inverter control stack control electronik for hand operator remote control HDR-Q1 (optional)

Fan

STICK 350

040-000427-00001

072-000417-00000

040-000495-00000

040-000427-00001

040-000433-00000

080-000297-00004

040-000470-00001

040-000290-00024

094-002476-00000

074-000267-00000

9/5


8.4.2

Von oben / from the top side

15

5 6 5 7 8

Pos.

5

6

7

8

15

Bezeichnung

Leiterplatte Treiberelektronik TRI4

Leiterplatte Primärschalter 2DW7.5

Inverter Steuersatz Primärseite

DW7,5/380/1

Leiterplatte Sperrwandler

SPW2/380V/1

Netzfilter NEF2


Description

PCB for the driver electronics

PCB primary switch

Inverter control stake primary side

Primary control PCB

Mains filter

8.4.3

Linke Seite / left side side

13 12

11

10 9 10 9

STICK 350

040-000503-00000

042-000411-00000

040-000303-00000

040-000289-00000

040-000505-00000

14

12

13

14

Pos.

9

10

11


Bezeichnung Description

Primärschalter Minus (2xbestückt)

INV50/1000.6M

Primärschalter Plus (2xbestückt)

INV50/1000.6P

Varistor Schutzbeschaltung für

Netzgleichrichter SB460/6

Primary switch

Primary switch

Varistor modules, protective circuit for mains rectifier

Thyristor Dioden Modul MTD55-14A Thyristor diodes module

Netzgleichrichter B6 75/16 Mains rectifier

Magnetschalter Magnet switch

STICK 350 STICK 350 PWS

080-000294-00000

080-000295-00000

072-000292-00000

-

064-000083-00014

080-000204-00016

094-002757-00000

9/6

9 Accessories

9 Accessories

9.1

Remote control

9.1.1

STICK 250 H-2 / 350 CEL / 350 CEL / 350 CEL KLR / 350 CEL PWS

Designation

FR30

FR30

FRF30

FRF30

FR35

FR35

FRA40

FR 21

FRV 10

Description

Electric remote control with holding magnet, 5m




Hotstart remote control with holding magnet, 5m

Hotstart remote control with holding magnet, 10m

Electric remote control display, 0.3m

Foot-operated electric remote control, 5m

Connection cable extension, 10m

Item No.

090-008005-00000

090-008005-00010

090-008057-00000

090-008057-00010

090-008044-00000

090-008044-00010

090-008032-00000

094-000051-00000

092-000005-00001

9.1.2

STICK 350 CEL PWS

Designation Description

FR30PWS

FR30PWS

FRF30 PWS

FRF30 PWS



Remote control with holding magnet, 5m

Remote control with holding magnet, 10m

Item No.

090-008039-00000

090-008039-00010

090-008061-00000

090-008061-00010

9.2

General accessories

9.2.1

STICK 250 H-2

Description

16A CEE plug

Workpiece lead, 35mm

2

, 4m, pole binder

Electrode holder, 35mm

2

, 4m

9.2.2

STICK 350 CEL / 350 CEL / 350 CEL KLR / 350 CEL PWS

Description

32A CEE plug

Workpiece lead, 50mm

2

, 4m, pole binder

Electrode holder, 50mm

2

, 4m

Item No.

094-000712-00000

092-000008-00000

092-000052-00000

Item No.

094-000207-00000

092-000003-00000

092-000004-00000

10/1

10 Schaltpläne / Circuit Diagrams


10.1

STICK 250 H-2

10/1


10.2

STICK 350 CEL

10/2


10.3

STICK 350 CEL KLR

10/3


10.4

STICK 350 CEL PWS

10/4

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