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: info@ewm.de
Operating Instructions
GB
inverter
STICK-Schweißgeräte
from 350A to 450A,
portable
inverter
STICK 350
inverter
STICK 350 PWS
inverter
STICK 450
N. B. These operating instructions must be read before commissioning.
Failure to do so may be dangerous. Machines may only be operated by personnel who is
familiar with the appropriate safety regulations.
The machines bear the conformity mark - and thus comply with the
· EC Low Voltage Guideline (73/23/EEC)
· EC EMV Guideline (89/336/EEC)
(The CE Mark is only required in EC member states)
S
In compliance with VDE 0544 (EN 60974-1), the machines can be used in environments with
an increased electrical hazard.
© 2000 We reserve the right to make amendments. art. no.: 099-002015-EWM01 Revised: 28.08.2000
Originaldokument
liegt jedem Gerät bei!
Original document
is enclosed with each machine!
Document original
est joint à toute machine!
EG - Konformitätserklärung
EU - conformity declaration
Déclaration de Conformidité 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)
Anschrift des Herstellers:
Address of manufacturer:
Adresse du fabricant:
Dr.- Günter - Henle - Straße 8
D - 56271 Mündersbach – Germany
info@ewm.de
Hiermit erklären wir, daß das nachstehend
bezeichnete Gerät in seiner Konzeption und
Bauart sowie in der von uns in Verkehr gebrachten Ausführung den grundlegenden
Sicherheitsanforderungen der unten genannten
EG- Richtlinien entspricht. Im Falle von
unbefugten Veränderungen, unsachgemäßen
Reparaturen und / oder unerlaubten Umbauten,
die nicht ausdrücklich von EWM autorisi ert sind,
verliert diese Erklärung ihre Gültigkeit.
We herewith declare that the machine described
below meets the standard safety regulations of the
EU- guidelines mentionned below in its conception
and 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.
Par la présente, nous déclarons que la conception
et la construction ainsi que le modéle, mis sur le
marché par nous, de l´appareil décrit ci - dessous
correspondent aux directives fondamentales de
sécurité de la U.E. mentionnées ci- dessous. En cas
de changements non autorisés, de réparations
inadiquates et / ou de modifications prohibeés, qui
n´ont pas été autorisés expressément par EWM,
cette déclarati on devient caduque.
Gerätebezeichnung:
Description of the machine:
Déscription de la machine:
Gerätetyp:
Type of machine:
Type de machine:
Artikelnummer EWM:
Article number:
Numéro d´article
Seriennummer:
Serial number:
Numéro de série:
Optionen:
Options:
Options:
keine
none
aucune
Zutreffende EG - Richtlinien:
Applicable EU - guidelines:
Directives de la U.E. applicables:
EG - Niederspannungsrichtlinie (73/23/EWG)
EU - low voltage guideline
Directive de la U.E. pour basses tensions
EG- EMV- Richtlinie (89/336/EWG)
EU- EMC guideline
U.E.- EMC directive
Angewandte harmonisierte Normen:
Used co-ordinated norms:
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
contents /1
Safety instructions................................................................................................................................Safety/1
For your safety ..................................................................................................................................Safety/1
Transport and set-up...............................................................................................................................Safety/3
Notes on the use of these operating instructions....................................................................................Safety/3
General .........................................................................................................................................AI/1
1 Technical data..................................................................................................................................... 1/1
2 Description of the machine................................................................................................................ 2/1
3 Function specification (logic control)............................................................................................... 3/1
3.1 Function specification (logic control) .......................................................................................... 3/1
3.2 Function sequence MMA welding............................................................................................... 3/2
3.3 Remote controls ......................................................................................................................... 3/3
4 Commissioning................................................................................................................................... 4/1
4.1 Setting up the welding machine.............................................................................................. .... 4/1
4.2 Mains connection........................................................................................................................ 4/1
4.2.1 Reconnecting the mains voltage 400/415V at the control transformer (PWS only)......... 4/1
4.3 Welding machine cooling system............................................................................................... 4/2
4.4 Workpiece lead........................................................................................................................... 4/2
4.5 Electrode holder con ne ction (MMA w eldi ng).............................................................................. 4/2
5 Maintenance and care ........................................................................................................................ 5/1
6 Operating problems, causes and remedies..................................................................................... 6/1
6.1 Customer checkli st .....................................................................................................................6/1
7 Spare parts list....................................................................................................................................7/1
8 Circuit diagrams.................................................................................................................................. 8/1
Safety instructions
Safety/1
For Your Safety:
Observe accident prevention regulations.
Ignoring the following safety procedures can be fatal.
· Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves.
· Protect eyes and face with protective visor.
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.
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.
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.
Safety instructions
Safety/2
Take care to avoid fire hazards
· 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.
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 redu ctio n m easu res:
· 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.
Safety instructions
Safety/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.
Environmental conditions:
The welding machine can be operated in a location where there is no risk of explosion at
· an ambient temperature of -10°C (plasma machines 0°C) to +40°C and
· a relative air humidity 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 penetr ation of sol id 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 (S ect . 5, G2) and lock.
Meaning of the diagram descript io ns:
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
General
AL/1
About this machine manufactured in inverter technology
Congratulations.
You have purchased a modern and efficient welding machine in inverter technology.
In contrast to conventional welding current sources, it does not operate with 50Hz but with a 50kHz
primary-switch transistor current source.
You can now exploit the advantages of this inverter technology:
· Less effort in changing to another wor kpla ce be cau se the machine dime ns ion s and wei ght are
substantially reduced.
· Lower current consumption and smaller mains ratings by higher efficiency (lower losses).
· No need for expensive compensating equipment by a high cos phi and a correspondingly
smaller reactive current draw from the mains.
· Functional safety by robust construction and highly integrated electronic circuitry.
· High control dynamics for the welding process. Therefore, excellent welding and fusing results
and absolute reproducib il ity of al l weld ing parameters.
· Welding results independent of mains voltage fluctuations.
· Easy to service design by the use of modern, modular technology.
· Adjustable arcforcing to adapt to any stick electrode welding task.
· Pole exchange switch for flexible and rapid work even when the stick electrodes are changed.
1 Technical data
1/1
inverter
STICK 350
inverter
STICK 350 PWS
inverter
STICK 450
Adjusting range Welding
current / voltage
5 A / 20.2 V -
350 A / 34 V
5 A / 20.2 V -450 A /
38 V
Efficiency
91%
Welding current at
60% DC of electrode
350A 450A
Welding current at
100% DC of electrode
270A 350A
Load alternation
10min (60% DC
Ù
6 min. welding, 4min. break)
Open circuit voltage
109V 78V
Mains voltage ( tolerances )
3x400V (+ 20% to - 25% )
3x415V (+ 15% to - 25% )
Mains frequency
50 - 60Hz
Mains fuses, slow-blow
3 x 25 A 3 x 35 A
cos j
jj
j
0,99
Ambient temperature
-10
° C to 40°C
Protection classification
IP 23
Insulation class
H
Dimensions L/W/H incl.
handle
550mm x 370mm x
520mm
550mm x 370mm x
590mm
550mm x 440mm x
520mm
Weight
48kg 60kg 62kg
Built to
VDE 0544 Part 1 (EN 60974-1)
S
In compliance with VDE 0544 (EN 60974-1), this welding machine can be used in environments with
an increased electrical ha zar d.
2 Description of the machine
2/1
A
A
D
E
F
G
H
I
J
K
L
B
C
Fig. 1: Front view
Inverter
STICK 350 PWS
A Carrying handle
B Main power switch
C Rubber feet
5A
Hot
100
50
150
300A
200
250
D Hotstart current rotary dial
E Yellow LED, excess temperature
250
300A
50
5A
100
150
200
F Potentiometer for adjusting the welding current
t
Hot
0
0.5
sec.
2
1.5
1
G Hotstart time rotary dial
RUTIL
CELL
BASISCH
H Arcforcing rotary dial
Pole changeover switch (
inverter
STICK 350 PWS only )
ONOFF
I
or
Changeover switch: Cableless remote control "ON/OFF"
(
inverter
STICK 350/450 KLR only)
J Remote control connection
K Welding current socket "-"
(negative polarity in pole changeover switch position "-",
inverter
STICK 350
PWS only)
L Welding current socket "+"
(positive polarity in pole cha nge ov er sw it ch pos it ion "-",
inverter
STICK 350
PWS only)
3 Function specification
3/1
3.1 Function specification (logic control)
Fig. 2:
Logic control
Inverter
STICK 350 PWS
Q
250
300A
50
5A
100
150
200
Main current I
1
The main current I1 can be adjusted infinitely from 5A to the maximum
welding current.
2
5A
Hot
100
50
150
300A
200
250
Hotstart current
The hotstart device makes it possible to ignite and re-ignite critical stick
electrodes without difficulty. Hotstart current setting I
Hot
infinitely
adjustable from 5A to the maximum welding current
3
t
Hot
0
0.5
sec.
2
1.5
1
Hotstart time
The hotstart time t
Hot
is adjusted infinitely from 0sec. to 2sec.
Hotstart device
The hotstart device makes it possible to ignite and re-ignite critical
stick electrodes without difficulty. The hotstart current and time are also
externally adjustable with the remote control FR 35.
4
Signal light, excess temperature (yellow)
Indicates an excess temperature of the welding machine and
extinguishes when this has cooled. Excess temperature occurs when
the duty cycle is exceeded or if the ventilation slots are obstructed.
3 Function specification
3/2
5
RUTIL
CELL
BASISCH
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 current increase depends on the setting of the arcforce
potentiometer. Excellent welding results are achieved with all difficult types
of electrode by arcforcing.
"Far left" position: Low arcforcing
Þ smoother arc,
low current increase before the shortcircuit. Used with stick electrodes
enveloped with rutile.
"Centre" position: Medium arcforcing
Þ normal arc,
medium current increase before the
Short-circuit. Used for alkaline coated
stick electrodes.
"Far right" position: High arcforcing
Þ hard arc,
high current increase before the shortcircuit. Used with cellulose stick electrodes.
Functional specification Antistick:
If the stick electrode sticks in spite of the arcforcing device, the machine
automatically switches over to the minimum current within about 1 sec, so
that the annealment of the electrode is prevented.
If the antistick device has responded, check the welding current setting and
if necessary corre ct it.
6
Pole exchange changeover switch (
inverter
STICK 350 PWS only)
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
( + )
or
6
ONOFF
Changeover switch: Cableless remote control "ON/OFF"
(
inverter
STICK 350/450 KLR only)
Switch position ON welding current setting by remote control
Switch position OFF welding current setting on the welding machine
3 Function specification
3/3
3.2 Function sequence MMA welding
When the stick electrode has been struck, the arc ignites at the adjusted hotstart current I
Hot
and
welds with this current until the expiry of the hotstart time t
Hot
. The hotstart current then falls to
the adjusted main current I
1
and remains constant unt il weldi ng is co mp let ed. ( see pro ce ss ch ar t
below)
If the electrode sticks in the welding pool for longer than 1 sec, the antistick device comes into
effect. Check the welding current setting and correct according to the welding task.
Welding current
Hotstart current
I
Hot
Main current
I
1
Hotstart time
I
t
Fig. 3:
Process chart for stick electrodes - welding with the hotstart device
3 Function specification
3/4
3.3 Remote controls
Only the remote controls described in these operating instructions may be connected!
Plug the remote control into the remote control socket of the welding machine (Chap. 2, J)
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 of the remote control for detailed information.
Foot-operated remote control FR 21
Functions
· The welding current I
1
is adjustable in absolute values from the minimum to the
maximum current depending on the welding current selected on the machine.
Manual remote control FR 30
Functions
· The welding current I
1
is adjustable in absolute values from the minimum to the
maximum current depending on the welding current selected on the machine.
Manual remote control FR 30F
Functions
· The welding current I
1
is adjustable in absolute values from the minimum to the
maximum current depending on the welding current selected on the machine.
The welding current I
1
is adjustable in 2 ranges for this
(coarse/fine adjustment)
Features
· Large adjusting knob
Manual remote control FR 30 PWS
Functions
· Pole changeover switch to change the welding polarity.
The welding current I
1
is adjustable in absolute values from the minimum to the
maximum current depending on the welding current selected on the machine.
Commissioning:
· The pole changeover swi tch of the mach ine must be in position +.
3 Function specification
3/5
Manual remote control FR 30F PWS
Functions
· Pole changeover switch to change the welding polarity.
The welding current I
1
is adjustable in absolute values from the minimum to the
maximum current depending on the welding current selected on the machine.
The welding current I
1
is adjustable in 2 ranges for this (coarse/fine adjustment).
Commissioning:
· The pole changeover switch of the mach ine must be in position +.
Features
· Large adjusting knob
Cableless manual remote control FR 30 KL
Functions
· The welding current I
1
is adjustable in absolute values from the minimum to the
maximum current depending on the welding current selected on the machine.
Commissioning:
· The changeover switch of the welding machine must be in position ON (cableless
remote control active)
Features
· Welding current adjustment without connecting cable
Manual remote control FRA 40
Functions
· The welding current I
1
is adjustable in absolute values from the minimum to the
maximum current depending on the welding current selected on the machine.
· The machine can be switched from remote control FRA 40 (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 contro l, se tti ng when su pp li ed: 250 A)
Features
· LED welding current display .
· 10-turn helical potentiometer for accurate setting of welding current.
· Connection facility for further remote controls.
Manual remote control Hotstart FR 35
Functions
· Remote control "ON/OFF" (changeover switch on the remote control).
· Hotstart current and hotstart time inf in ite ly ad ju stab le.
· The welding current I
1
is adjustable in absolute values from the minimum to the
maximum current, i.e. regardless of the welding current selected on the machine.
Commissioning:
· The welding current I
1
is adjustable in absolute values from the minimum to the
maximum current depending on the welding current selected on the machine.
· Switch on the remote control.
Features
· Connection facility for remote control FRA 40.
When the FR35 is in use, the hotstart current and time must be set to
their minimum values on the welding machine.
4 Commissioning
4/1
4.1 Setting up the welding machine
Follow safety instructions on the opening pages entitled " For Your Safety".
· Set up the machine so that there is enough room to adjust the operating elements.
· Ensure that the machine is set up in a stable position and appropriately secured.
4.2 Mains connection
The operating voltage shown on the rating plate must be consistent with the mains voltage!
For mains fuse, please refer to the technical data (Chap. 1)!
· Insert mains plug of the switched-off machine into the appropriate socket.
4.2.1 Reconnecting the mains voltage 400/415V at the control transformer
(PWS only)
Follow safety instructions on the opening pages entitled " For Your Safety".
The Faston plug (arrow) must be set on the transformer according to the mains voltage.
· For 400V: Connect plug to pin 4 (works setting),
· For 415V: Connect plug to pin 6.
415V400V
0V
Fig.: Control transformer
Machines delivered to countries with mains
voltages which deviate from the standard are
marked with the following labels:
a)
Indication of the mains voltage (at the end of the
cable)
b)
Mains voltage on delivery
(rear of the unit above the rating plate)
Netzanschlußspannung
Mains voltage
400V
c) Special voltages, for marking according to
reconnecting on site (enclosed with the operating
instructions)
After reconnecting for 415V,
· label c) must be taped over label b) and
· label a) must be removed from the end of the
cable.
230V 230V
400V 400V
415V 415V
460V 460V
500V 500V
___V ___V
460V
500V
41
400
415
c)
(Art. No. label, see accessory list)
4 Commissioning
4/2
4.3 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 machine’s air inlets and outlets,
· Metal parts, dust or other foreign bodies must not get into the machine.
4.4 Workpiece lead
Remove paint, rust and dirt from clamping and welding areas with a wire brush! Attach the
workpiece clamp in the immediate vicinity of the welding position! Structural parts, pipes,
rails etc. may not be used as return leads for the welding current if they are not the
workpiece themselves!
A perfect current connection must be ensured where welding benches and appliances are
concerned!
· Insert cable plug of the workpiece lead into the welding current socket "+" (Chap. 2, Item L) or
"+" (Chap. 2, Item M) and lock by turning to the right.
The polarity depends on the instructions of the electrode manufacturer.
4.5 E l ectrode holder connection (MMA welding)
· Insert cable plug of the stick electrode holder into the welding current socket "+" (Chap. 2, Item
M
) or "-" (Chap. 2, Item L) and lock by turning to the right.
The polarity depends on the instructions of the electrode manufacturer.
5 Maintenance and care
5/1
Under normal operating conditions these welding machines are largely maintenance-free and
require a minimum of care. However, a number of points should be observed to guarantee faultfree operation of your welding machine. Among these are regular cleaning and checking, as
described below, depending on the level of contamination in the environment and the usage time of
the welding machine.
Cleaning, testing and repairing of the welding machines may only be carried out by
competent personnel. In the event of failure to comply with any one of the following tests the
machine must not be operated again until the fault has been rectified.
5.1 Cleaning
To do this, carefully disconnect the machine from the mains. PULL OUT THE MAINS PLUG!
(Switching off or unscrewing the fuse is not adequate isolation).
Wait for 2 minutes until the capacitors have discharged. Remove the casing cover.
The individual components should be handled as follows:
· Current source Depending on the amount of dust, blow out current source using oil-and
moisture-free compressed air.
· Electronics, circuit boards Do not blow on electronic components with the compressed air
stream but suck clean using a vacuum cleaner.
5.2 Repetition test according to VDE 0702 and VBG 15
The following description of the repetition test is merely an extract from the detailed test
instructions. If required, a copy can be requested from us!
You are recommended to carry out a quarterly and an annual check. The annual test should also
be carried out after every repair. Test sequence:
Quarterly test:
· Visual check of correct condition
· Measurement of protective conductor resistance
Annual test:
· Visual check of correct condition
· Measurement of protective conductor resistance
· Measurement of insulation resistance following internal cleaning of the power source
· Measurement of the open circuit voltage
· Function test of the welding machine
5.2.1 Visual check of correct condition
The machine must be inspected for externally visible faults (without opening the machine). During
this inspection, attention must be paid, for example, to the following points:
· External faults in mains plug and mains cab le, e.g. insul at io n fault s, s corc h or pres sur e mar ks.
· Defects in anti-kink protection and the strain relief of the connection lead, mains switch.
· Faults in welding leads, tube package, plug fixture, arc torch.
· Signs of an overload and improper use.
· Damage to stop points and casing.
· Improper interference and modifications.
· The type plate and warn ing s ymb ol mu st be prese nt and le gib le.
Die im Kapitel
"Wartung und Pflege" aufgeführten Hinweise, Richtlinien und Normen wurden
grundlegend überarbeitet und sind aus diesem G
rund nicht mehr gültig!
Die relevanten Hinweise, Richtlinien und Normen finden Sie in den
beiliegenden
Ergänzungsblättern "Allgemeine Hinweise zu 3 Jahre G
arantie", Art. Nr.: 099-000GAR-EWMxx.
Sollten die Dokumente nicht vorliegen, können diese über den autorisierten Fachhändler
angefordert werden!
Außerachtlassung kann lebensgefährlich sein!
The instructions, guidelines and standards given in the "Maintenance and Care" chapter have
been completely revised and are therefore no longer valid!
The relevant instructions, guidelines and standards can be found in the enclosed supplements
"General notes on the 3 year warranty",item no.: 099-000GAR-EWMxx.
If these documents are missing, they can be reque
sted from your authorised specialist dealer!
Not observing these instruc
tions can be potentially fatal!
Les consignes, directives et normes indiquées au chapitre « Maintenance et entretien » ont été
mises à jour et ne sont donc plus valables !
Vous trouverez les consignes, directives et normes applica
bles dans les additifs « Consignes
généra
les relatives
à la garantie de 3 an
s », à l´article : 099-000GAR-EWMxx.
Si vous ne possédez pas les documents, vous pouvez vous les procurer auprès de votre
revendeur autorisé !
Le non-respect des consignes peut représenter un danger de mort !
Le istruzioni, direttive e norme presenti nel capitolo „
Manutenzion
e e cura” sono state
completamente riviste e per questo motivo non sono più valide!
Le istruzioni, direttive e norme rilevanti le trovate nell'aggiornamento qui allegato “Is
truzioni
generali sui 3 anni di
garanzia”, Nr. Art.: 099-000GAR-EWMxx.
Se i documenti non fossero disponibili, possono
essere richiesti al rivenditore autorizzato!
L'inosservanza delle istruzioni può comportare pericolo di vita!
D
F
GB
I
5 Maintenance and care
5/2
5.2.2 Measurement of protective conductor resistance
Measure between safety contact of the mains plug and metal parts which can be touched, e.g.
casing screws.
During measuring, the entire length of the machine’s connection lead, especially near the
connection points, must be moved.
The resistance must be < 0.1
W. The measurement must be performed using at least 200 mA.
5.2.3 Measurement of insulation resistance
The machine must be disconnected from the mains!
Open the welding machine and clean it carefully (as described below).
Switch on mains swit ch .
· Insulation resistance mains current circuit - casing: Measure from a connection of the
mains plug to the casing. The resistance must be > 2.5 M
W.
· Insulation resistance welding current circuit - casing: Measure between a welding socket
and protective conductor. The resistance must be > 2.5 M
W.
· Insulation resistance mains current circuit - welding current circuit: Measure from a
connection of the mains plug to a welding current socket. The resistance must be > 5.0 M
W.
5.2.4 Measurement of open circuit voltage
(according to EN 60974-1 / VDE 0544 T1)
-
+
6u8F
10nF
0...5k
Meqsurement circuit for peak values
Input
0k2
1k0
Diode similar 1N 4007
V
Connect the measuring circuit to the
welding current sockets as shown in Fig. 1.
The voltmeter must indicate the mean
value. Adjust the potentiometer from 0k
W to
5k
W during the measurement.
The measured voltage must not deviate
from that specified on the rating plate (U
0
)
by more than 10%.
5.2.5 Function test of the welding machine
Carry out a function test depending on the type of machine.
5.3 Repair work
Repair and maintenance work may only be performed by qualified personnel.
In all service matters, always consult your dealer.
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 maintenance or repair 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 lapses.
6 Operating faults, causes and remedies
6/1
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 leads to the correct functioning of the machine,
please inform your authorised dealer.
Customer checklist
Switch on machine at the mains
switch
Yes
Machine is operative (fan running) No
Mains supply interrupted
Mains plug not inserted
Mains plug wrongly connected
Mains fuse faulty
Mains switch faulty
Excess temperature, yellow LED lights
(allow machine to cool)
Yes
Welding current No
Electrode holder or workpiece lead not
connected
Yes
Good welding properties No
Wrong material composition
Electrodes and workpi ece lead s
misconnected (follow manufacturer’s
instructions for electrodes)
Electrode not clean, incorrect switch
position PWS +/-.
Yes
Remote control functions No
Remote control plug not connected to the
machine
Remote control or cable defective
7 Spare parts list
7/1
Fig. 1, front
Designation Type
STICK 350 STICK 350 PWS STICK 450
1 Main switch
B2N-A-F15-B
D200-F15-B-SI
074-000279-00001
094-000525-00000
Switch knob
094-001814-00000
2 Rotary dial
Æ23mm / 2523060
074-000315-00000
Rotary dial cover
Æ23mm / 4123002
074-000315-00001
Rotary dial arrow
indicator
Æ23mm / 4223002
074-000315-00002
3 Rotary dial
Æ31mm / 2531060
074-000234-00000
Rotary dial cover
Æ31mm / 4131002
074-000234-00001
Rotary dial arrow
indicator
Æ31mm / 4231002
074-000234-00002
4
Changeover
switch:
000100.2901 - 044-001939-00000 -
(KLR units only) 1631/1pole OFF 094-001898-00000 - 094-001898-00000
5 PCB connector
board
EB 3 040-000408-00000
6 Socket built-in
DIXBE/70-95qmm 074-000232-00000 074-000517-00000
7 Spare parts list
7/2
Fig. 2, rear
Designation Type
STICK 350 STICK 350 PWS STICK 450
7 Grip
1095 - 07 074-000237-00000
8 Tube: steel
1095-1203/30x1.5x440mm
074-000237-00008
9 Feet: rubber
40x35/M8/thread
height 7mm
074-000223-00000
0 Fuse
1.25A slow-blow/250V - 094-000430-00000 -
1 Angular casing
094-004226-00006 094-003584-00007 094-000840-00005
2 Cable rubber
4x2.5qmm/HO7RN-F
4x4qmm/HO7RN-F
094-000365-00000
094-000404-00000
3 Label, mains
connection
voltage
- 094-007249-00000 -
7 Spare parts list
7/3
Fig. 3, side view left
Designation Type
STICK 350 STICK 350 PWS STICK 450
1
IND control
transformer
EI84a/60VA - 094-000615-00001 -
2 Switch: Magnet
EL-MA/320/EBC - 094-000722-00000 -
3 Inverter kit
STICK DC 34V/ 350A3x400V/415V-L
STICK DC 38V/ 450A3x400V/415V-L
070-000079-00001
070-000059-00001
5
Thyristor diode
module
MTD55-14A 064-000083-00014
6 PCB power
supply unit
blocking
converter
SPW2/380V/1 040-000289-00000
7 Isodul / primary
rectifier
B6 75/16 080-000204-00016
9
Multidul
Darington
transistor
INV50/1000-6M 080-000294-00000
0 PCB inverter
driver
electronics
TRI4 040-000503-00000
1 Multidul
Darington
transistor
INV50/1000-6P 080-000295-00000
7 Spare parts list
7/4
Fig. 4, side view right
Designation Type
STICK 350 STICK 350 PWS STICK 450
2 PCB welding
electronics
STICK 1/3 040-000415-00000
3 PCB welding
electronics
FAL 1/AF 040-000470-00001
4 Isodul diode -
fast
MDDM120-04F02 080-000257-00004
5 PCB protective
wiring
DSB 3/4
DSB 3/1
040-000427-00000
040-000297-00000
6
PCB Inverter
control stack
TRDC2/350/7
TRDC2/450/1
040-000290-00016
040-000290-00012
7 PCB protective
wiring
DSB1/2
DSB1/1
040-000433-00000
040-000298-00000
8 Schaltpläne / Circuit Diagrams
8/1
8.1
inverter
STICK 350 / 450
(Schaltpläne befinden sich ebenfalls im Gerät)
8 Schaltpläne / Circuit Diagrams
8/2
8.2
inverter
STICK 350 PWS
8 Schaltpläne / Circuit Diagrams
8/3
8.3
inverter
STICK 350 / 450 KLR
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