EWM TRITON 260 DC, TRITON 400 DC, TRITON 500 DC 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:

info@ewm.de

Operating instructions

Multi-process welding machines for

TIG welding

MMA welding

MIG/MAG welding (option)

• TRITON 260 DC

• TRITON 400 DC

• TRITON 500 DC

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)

In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments with an increased electrical hazard.

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 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)

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 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.

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 modificati ons, which have not been expressly allowed by E WM, this declaration will lose its validity.

Par la présente, nous déclarons que la conception et la construc tion ainsi que le modèle, 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 inadéquates et / ou de modifications prohibeés, qui n´ont pas été autorisés expressément par EWM, cette déclaration 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

Inhalt/1

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

For Your Safety..........................................................................................................................S/1

Transport and set-up..................................................................................................................S/4

Notes on the use of these operating instructions....................................................................... S/4

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

1.1 TRITON 260......................................................................................................................1/1

1.2 TRITON 400/500 ..............................................................................................................1/2

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

2.1 TRITON 260......................................................................................................................2/1

2.1.1 Front view.............................................................................................................2/1

2.1.2 Rear view.............................................................................................................2/2

2.2 TRITON 400/500 ..............................................................................................................2/3

2.2.1 Front view.............................................................................................................2/3

2.2.2 Rear view.............................................................................................................2/4

3 Function specification..............................................................................................................3/1

3.1 Operating elements, control T101 ....................................................................................3/1

3.1.1 Additional operating elements TRITON 260 (MIG/MAG option)..........................3/2

3.1.2 Additional operating elements TRITON 400/500 (MIG/MAG option)...................3/3

3.2 TIG welding, general.........................................................................................................3/4

3.2.1 Types of ignition...................................................................................................3/4

3.2.2 Automatic shut-off................................................................................................3/4

3.2.3 Digital display.......................................................................................................3/4

3.2.4 TIG welding torch, operating variants..................................................................3/5

3.2.5 Tapping operating mode......................................................................................3/5

3.3 TIG function sequences ...................................................................................................3/6

3.3.1 Explanation of symbols........................................................................................3/6

3.3.2 TIG non-latched operation...................................................................................3/7

3.3.3 TIG latched operation ..........................................................................................3/8

3.4 TIG pulses, function sequences ......................................................................................3/9

3.4.1 TIG pulses - non-latched operation......................................................................3/9

3.4.2 TIG pulses - latched operation...........................................................................3/10

3.5 MMA welding ..................................................................................................................3/10

3.5.1 TRITON 260 adjustable arcforcing ....................................................................3/10

3.5.2 TRITON 400/500 adjustable arcforcing.............................................................3/11

3.6 MIG/MAG welding (Option).............................................................................................3/11

3.6.1 TRITON 260 (Option).........................................................................................3/11

3.6.2 TRITON 400/500 (Option)..................................................................................3/12

3.7 Remote control................................................................................................................3/13

3.8 TIG interface for mechanised welding (remote control connection socket)....................3/14

3.9 Welding parameter adjustments "internally"...................................................................3/15

3.9.1 P10: Gas pre-flow time ......................................................................................3/15

3.9.2 P1: I-start Ignition current...................................................................................3/16

3.9.3 P2: t-UP Up-slope time ......................................................................................3/16

3.9.4 JP5: Switching between normal or tapping operation........................................3/16

3.9.5 S3 tPulse and S4 tPause TIG pulses, pulse and break time adjustment..........3/16

3.9.5.1 S3 tPulse pulse time ........................................................................3/16

3.9.5.2 S4 tPause Pulse break ....................................................................3/16

3.9.5.3 Example of settings for the pulse and pulse break times ................3/16

3.10 Programming of the torch operation variants .................................................................3/17

3.10.1 Mode 1, standard operation (works setting) with standard TIG torch................3/17

3.10.2 Mode 2, Up/Down operation for standard torches with a rocker .......................3/17

3.10.3 Mode 3, Up/Down operation for standard torches with two triggers..................3/18

3.10.4 Setting the Up/Down speed...............................................................................3/18

3.11 Returning the machine to the works settings..................................................................3/18

3.12 JP13, JP14 and JP15: Configure welding torch connection...........................................3/19

3.13 TRITON 400/500 interface for mechanised MIG/MAG welding (option)........................3/20

Table of contents Page

Inhalt/2

4 Quick start – the shortest way to welding..............................................................................4/1

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

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

5.1.1 TRITON 260.........................................................................................................5/1

5.1.2 TRITON 400/500 .................................................................................................5/1

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

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

5.3.1 Reconnecting the mains voltage 400/415V and 440/460V..................................5/1

5.4 Welding machine cooling system .....................................................................................5/2

5.5 Workpiece lead, general...................................................................................................5/2

5.6 Connection groups............................................................................................................5/2

5.7 MMA welding ....................................................................................................................5/2

5.7.1 Electrode holder...................................................................................................5/2

5.7.2 Workpiece lead ....................................................................................................5/3

5.8 TIG welding.......................................................................................................................5/3

5.8.1 Welding torch, general.........................................................................................5/3

5.8.1.1 Standard TIG torch.............................................................................5/4

5.8.1.2 TIG Up/Down or TIG potentiometer welding torch.............................5/4

5.8.2 Shielding gas supply (shielding gas cylinder to the welding machine)................5/4

5.8.3 Workpiece lead ....................................................................................................5/4

5.9 MIG/MAG welding (option) ...............................................................................................5/5

5.9.1 TRITON 260 ........................................................................................................5/5

5.9.1.1 Supply to the wire feed unit................................................................5/5

5.9.1.2 Workpiece lead ..................................................................................5/5

5.9.2 TRITON 400/500..................................................................................................5/5

5.9.2.1 Supply to the wire feed unit................................................................5/6

5.9.2.2 Workpiece lead ..................................................................................5/6

5.10 Cooling unit function specification ....................................................................................5/6

5.10.1 Coolant error........................................................................................................5/6

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

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

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

8.1 TRITON 260 spare parts list.............................................................................................8/1

8.2 TRITON 400/500 spare parts list......................................................................................8/4

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

9.1 TRITON 260......................................................................................................................9/1

9.1.1 Standard TIG torch...............................................................................................9/1

9.1.2 TIG Up/Down torch ..............................................................................................9/1

9.1.3 Electrode holder /workpiece lead.........................................................................9/1

9.1.4 Remote control / connection cable.......................................................................9/1

9.1.5 Miscellaneous accessories ..................................................................................9/1

9.2 TRITON 400/500...............................................................................................................9/2

9.2.1 Standard TIG torch...............................................................................................9/2

9.2.2 TIG Up/Down torch ..............................................................................................9/2

9.2.3 Electrode holder /workpiece lead.........................................................................9/2

9.2.3.1 TRITON 400.......................................................................................9/2

9.2.3.2 TRITON 500.......................................................................................9/2

9.2.4 Remote control / connection cable.......................................................................9/2

9.2.5 Miscellaneous accessories ..................................................................................9/2

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

10.1 TRITON 260....................................................................................................................10/1

10.2 TRITON 400/500.............................................................................................................10/3

Safety instructions

S/1

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,

• mod ified or co nv er ted im properly

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.

Safety instructions

S/2

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.

Safety instructions

S/3

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

S/4

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 of -10°C (plasma machines 0°C) to +40°C and

• a relative air humidity up to 50% at 40°C.

• where the sur r ou ndi ng air is fr ee of unusual amounts of dust, acids, corrosive gases or

substances etc., insofar as they do not occur during welding. Examples of unusual operating condition s: 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 inle ts and outlets are unobstructed.

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

• Protection against penetratio n of sol id for e ign bod ie s ∅ > 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 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

1 Technical data

1/1

1.1 TRITON 260

TRITON 260 Setting range:

Welding current / voltage TIG, MMA MIG/MAG

5A/ 10.2V – 260A/ 20.4V 5A/ 20.2V – 230A/ 29.2V

5A/ 14.3 – 240A/ 26V

Max. welding current at TIG MMA MIG/MAG 20ºC ambient temperature: 50%DC

60%DC 100%DC

40ºC ambient temperature: 25%DC 35%DC 60%DC 100%DC

260A 240A 190A

260A 230A 170A 130A

230A 210A 160A

230A 200A 150A 110A

240A 220A 170A

240A 210A 160A 120A

Load alternation

10min (60% DC

∧

6 min welding, 4min break)

Open circuit voltage 93V Mains voltage (tolerances) 3 x 400V (-25% - +15%)

3 x 415V (-25% - +10%)

Frequency 50/60 Hz Mains fuse (safety fuse - slow-blow) 3 x 16A Mains connection lead 4 x 1.5mm2 Max. connected power 10.8kVA Recommended generator rating 14.6kVA cosϕ / efficiency

0.99 / 89%

Insulation class / Protection classification

H / IP 23

Ambient temperature

-10°C to +40°C

Machine cooling / Torch cooling Fan / Gas Workpiece lead 35mm2 Dimensions L/W/H [mm] 560 x 245 x 365 Weight approx. 24.5Kg constructed to standard

IEC 60974 / EN 60974 / VDE 0544 EN 50199 / VDE 0544 Teil 206

1 Technical data

1/2

1.2 TRITON 400/500

TRITON 400 TRITON 500 Setting range:

Welding current / voltage TIG, MMA MIG/MAG

5A/ 10,2V - 400A/ 26,0V 5A/ 20,2V - 400A/ 36,0V 5A/ 14,3V - 400A/ 30,0V

5A/ 10.1V -500 A/ 30.0V

5A/ 20.1V -500A/ 40.0V 5A/ 14.2V -500A/ 39.0V

Duty cycle at 40°C ambient temperature: 40%dc 60%dc 100%dc Duty cycle at 20°C ambient temperature: 40%dc 45%dc 60%dc 65%dc 100%dc

400A 360A 300A

400A

360A 300A

500A 450A 340A

500A

475A

390A

Load alternation

10min (60% DC

∧

6 min welding, 4min break)

Open circuit voltage 92V 79V at 400V

91V at 460V

Mains voltage (tolerances) 3 x 400V (-25% - +20%)

3 x 460V (-25% - +15%)

3 x 400V (-25% - +20%) 3 x 460V (-25% - +15%) 3 x 415V (-25% - +10%)

Frequency 50/60 Hz Mains fuse (safety fuse - slow-blow) 3 x 35A Mains connection lead 4 x 4mm2 Max. connected power 21,5kVA 29 kVA Recommended generator rating 29,0kVA 39.2kVA cosϕ / efficiency

0.99 / 89%

Insulation class / Protection classification

H / IP 23

Ambient temperature

-10°C to +40°C

Machine cooling / Torch cooling Fan / Gas Workpiece lead 70mm2 95mm2 Dimensions L/W/H [mm] 625 x 335 x 560 Weight approx. 55kg approx. 58Kg constructed to standard

IEC 60974 / EN 60974 / VDE 0544 EN 50199 / VDE 0544 Teil 206

2 Description of the machine

2/1

2.1 TRITON 260

2.1.1 Front view

D1 E1

H1 I1

Fig. 2/1, Front view

Item Symbol Description

Carrying handle Carrying strap (no illustr.)

Operating elements (see control T101, chap. 3.1)

5-pole connection socket: Standard TIG torch control lead

8-pole connection socket: TIG Up/Down or potentiometer torch control lead

Welding current socket (welding current potential "+"):

MMA welding: Workpiece or electrode holder connection, TIG welding: Workpiece connection, MIG/MAG welding: Welding current connection to the WF unit or workpiece connection

Welding current socket (welding current potential "-"):

MMA welding: Workpiece or electrode holder connection

19-pole connection socket: Remote control connection

Welding current socket (welding current potential "-"):

TIG welding: Welding current connection for welding torch MIG/MAG welding: Welding current connection to the WF unit or workpiece connection

Connecting nipple G¼ (welding current potential"-") Shielding gas connection to the welding torch

Air inlet

Rubber feet

MIG/MAG operating elements (option), see chap. 3.1.1

2 Description of the machine

2/2

2.1.2 Rear view

E2 F2

G2 H2

Fig. 2/2, Rear view

Item Symbol Description

8-pole connection socket cooling unit control lead

Main switch Welding machine and where appropriate cooling module "On/Off"

Mains connection cable

7-pole connection socket wire feed unit control lead

Connecting nipple G¼ shielding gas connection to the pressure reducer

Types of ignition changeover switch

: Welding with HF ignition.

: Welding with Liftarc.

Changeover switch characteristics

Changing between each of two characteristics in the welding processes MMA: rutile / basic MIG/MAG: solid / cored wire

4-pole connection socket cooling unit voltage supply

I2 Air outlet

2 Description of the machine

2/3

2.2 TRITON 400/500

2.2.1 Front view

D3 E3

Fig. 2/3, Front view

Item Symbol Description

carrying handle

Main switch Welding machine and where appropriate cooling module "On/Off"

Operating elements (see control T101, chap. 3.1)

5-pole connection socket: TIG standard torch control lead

8-pole connection socket: TIG Up/Down or potentiometer torch control lead

Air inlet

19-pole connection socket: Remote control connection

Connecting nipple G¼ (welding current potential"-") Shielding gas connection to the welding torch

Welding current socket (welding current potential "-"):

TIG welding: Welding current connection for welding torch MIG/MAG welding: workpiece connection

Welding current socket (welding current potential "-"):

MMA welding: Workpiece or electrode holder connection

Welding current socket (welding current potential "+"):

MMA welding: Workpiece or electrode holder connection, TIG welding: workpiece connection

Rubber feet

MIG/MAG operating elements (option), see chap. 3.1.2

2 Description of the machine

2/4

2.2.2 Rear view

Fig. 4/2, Rear view

Item Symbol Description

7-pole connection socket wire feed unit control lead

8-pole connection socket cooling unit control lead

Connecting nipple G¼ shielding gas connection to the pressure reducer

Welding current socket - ; WF connection

Welding current socket +

Mains connection cable

4-pole connection socket cooling unit voltage supply

Types of ignition changeover switch

: Welding with HF ignition.

: Welding with Liftarc.

L4 Air outlet

3 Function specification

3/1

3.1 Operating elements, control T101

AMP

Puls

VOLT

T101

AMP

AMP %

sec

100

sec

Arcforce

K1 L1

H1 I1

Fig. 3/1: Control T101

Item Symbol Description

Changeover switch MMA / TIG welding process

= MMA welding

= TIG welding

The changeover switch (A2) must be switched to

TIG

MMA

TIG / MMA welding

Puls

TIG pulse /standard welding changeover switch

= TIG pulse = TIG standard welding

AMPAMP

VOLT

Digital display changeover switch

AMP = welding current display VOLT = welding voltage display

Digital display (lights up when machine is ready)

Displays the welding voltage or welding current, depending on the switch position (C1)

Non latched / latched operating mode changeover switch

= non-latched

= latched

AMP

"AMP" signal light Open-circuit or welding voltage on

AMP

"AMP" rotary dial Infinite adjustment of the welding current from 5A to maximum current

AMP %

0 100

"AMP%" rotary dial

The secondary current "AMP%" is infinitely adjustable in per cent of the main current "AMP" (G1). During the welding process, it is possible to switch from the main current

to the secondary current set at any time using the 2nd torch trigger

(for further operating variants see 3.2.4 TIG welding torch operating variants) .

3 Function specification

3/2

Item Symbol Description

sec

5 15

Gas post-flow time rotary dial The gas post-flow time is infinitely adjustable from 1 to 20 sec.

Red LED (collective interference)

If the collective interference LED lights up, the power unit is automatically switched off. Because some interferences are only brief and spurious (e.g. mains voltage surges), the LED extinguishes again and the welding machine is ready for welding. If the collective interference LED continues to be lit after an appropriate waiting time, see the chapter on troubleshooting.

Red LED (low coolant level) Indicates a low coolant level if the machine is operated with a cooling unit

Yellow LED (excess temperature)

Thermal monitors in the power unit trigger at excess temperature and the excess temperature indicator lamp lights. Welding can proceed without further measures after cooling.

5 15

sec

DOWN-SLOPE rotary dial

Lowering time of the main current AMP (G1) to the end-crater current I

end

(minimum current) infinitely adjustable from 0 to 20 sec.

Arcforce

Applies to MMA welding process only (TRITON 400/500 only) Selection of arcforcing, rutile, basic or cellulose.

3.1.1 Additional operating elements TRITON 260

GMAW

MIG/MAG

TIG

MMA

- +

Fig. 3/2: Operating elements front view

Item Symbol Description

GMAW

MIG/MAG

TIG

MMA

MIG/MAG or MMA / TIG welding process changeover switch

GMAW

MIG/MAG

= MIG/MAG welding (only possible with WF unit)

TIG

MMA

= TIG or MMA welding, selection on changeover switch (A1)

The welding process is preselected with this changeover switch.

- +

1 1

2 2

3 3

1 1

2 2

3 3

4+4

Rotary switch Dynamic correction / choke effect setting (for MIG/MAG only) hard / narrow (+) to soft / wide arc (-)

3 Function specification

3/3

3.1.2 Additional operating elements TRITON 400/500

0,8

1,2...1,6

0,8...1,0

1,2...1,6

0,8...1,0

Arcforce

G3/4Si1

CO 100%

G3/4Si1

Ar/Mix

FCAW

CrNi

1,0...1,6

Al/Cu

MIG/MAG

GMAW

TIG

MMA

GMAW

MIG/MAG

- +

Fig. 3/3: Operating elements front view

Item Symbol Description

GMAW

MIG/MAG

TIG

MMA

MIG/MAG or MMA / TIG welding process changeover switch

GMAW

MIG/MAG

= MIG/MAG welding (only possible with WF unit)

TIG

MMA

= TIG or MMA welding, selection on changeover switch (A1)

The welding process is preselected with this changeover switch.

- +

1 1

2 2

3 3

1 1

2 2

3 3

4+4

Rotary switch Dynamic correction / choke effect setting (for MIG/MAG only)

hard / narrow(+) to soft / wide arc(-)

Does not apply to TIG welding

1. Inner scale, MMA welding: Selection of arcforcing, rutile, basic or cellulose.

2. Outer scale; MIG/MAG welding Setting of the welding task according to the material, wire diameter and type of gas.

3 Function specification

3/4

3.2 TIG welding, general

If welding is performed alternately by different methods, e.g. TIG, MIG/MAG or MMA and if one or two welding torches and an electrode holder are connected to the machine, the open-circuit/welding voltage is applied simultaneously to both!

Therefore, always place the torch and the electrode holder on an insulated surface before starting work and during breaks.

3.2.1 Types of ignition:

HF ignition

The arc is started without contact by high-voltage ignition pulses.

Liftarc

The arc is ignited with contact with the workpiece:

a) The torch gas nozzle must be placed with its rim on the ignition point such that there is a gap of

approx. 2-3 mm between the electrode tip and the workpiece.

b) Carefully touch the workpiece with Tungsten electrode tip. Press torch trigger in accordance

with the operating mode selected.

c) The arc ignites when the torch is lifted off and swivelled into its normal position.

Fig. 3/3: Liftarc

3.2.2 Automatic shut-off

If ignition of the arc does not occur after starting or if the arc is interrupted when the torch is moved away, an automatic cut-out occurs after 3 sec. HF, gas and the open circuit voltage (power unit) are switched off.

3.2.3 Digital display

On the digital display (D1), the welding parameters

• welding current and

• welding voltage are shown.

Whether the welding current or welding voltage is to be displayed is selected on the changeover switch (C1).

3 Function specification

3/5

3.2.4 TIG welding torch, operating variants

The welding process can be controlled with various torch de signs (TT=torch trigger):

3.2.4.1 Standard TIG torch, 5-pole connection plug The welding machine is prepared for these torch types as standard.

Symbol Description Functions Operation with

Welding current On/Off TT 1

Standard TIG torch

Design: 1 trigger

secondary current TT 1 in tapping mode

Welding current On/Off TT 1 secondary current

TT 2

Standard TIG torch Design: 2 trigger

secondary current TT 1 in tapping mode Welding current On/Off TT 1 (rocker forwards)

secondary current TT 2 (rocker back)

Standard TIG torch Design: 2 triggers (MG rocker)

secondary current TT 1 (rocker forwards)

in tapping mode

Special functions with standard TIG torches such as e.g. Up/Down operation (see Chapter 3.10)

3.2.4.2 TIG Up/Down torch, 8-pole connection plug The welding machine is prepared for this torch type as standard.

Symbol Description Functions Operation with

Welding current On/Off TT secondary current TT in tapping mode

TIG Up/Down torch Design: 1 trigger + 2 triggers (rocker)

Increase / reduce welding current

Rocker forwards / rocker back

The last welding current set is stored in the memory and is available after switching on again.

3.2.4.3 TIG potentiometer torch, 8-pole connection plug Before commissioning, the welding machine must be converted for this type of torch!

(see Chapter 3.12)

Symbol Description Functions Operation with

Welding current On/Off TT secondary current TT in tapping mode

TIG potentiometer torch Design: 1 trigger + 1 wheel (potentiometer)

Increase / reduce welding current

Turn potentiometer backwards / forwards

3.2.5 Tapping operating mode.

The tapping mode was included particularly for the secondary current (AMP%) by the use of a trigger on the welding torch.

Torch with one trigger:

• by tapping (brief pressing and releasing) torch trigger 1

(Repeated tapping switches back to the main current).

Torch with two triggers:

There are two ways of switching to the secondary cu rrent:

• by tapping (see torch with one trigger)

• by pressing down and holding torch trigger 2.

Adjustment:

The "tapping operating mode" can be deactivated on the T101/1 circuit board (see Chap. 3.9.4).

3 Function specification

3/6

3.3 TIG function sequences

In the TIG operating modes, the following welding parameters can be adjusted via rotary dials:

• Main current AMP,

• Secondary current AMP%,

• Down-slope time,

• Gas post-flow time.

Other welding parameters are preadjusted to optimum settings for most applications, but can be changed internally (see Chapter 3.9).

3.3.1 Explanation of symbols

Symbol Meaning

Press torch trigger 1

Release torch trigger 1

AMP

Main current (5A to maximum current)

AMP% Secondary current (0% to 100% of AMP)

start

Ignition current (0% to 100% of AMP, adjustable internally, search arc at minimum

setting))

end

End-crater current = minimum current

tUp Up-slope time (adjustable internally)

Down

Down-slope time

TIG

MMA

TIG/MMA welding process (preselection for welding process)

TIG welding process

MMA welding process

Standard TIG welding (pulses switched off)

TIG pulses On Non-latched mode

Latched mode

HF ignition switched on

HF ignition switched off Gas pre-flows (adjustable internally)

Gas post-flows

3 Function specification

3/7

3.3.2 TIG non-latched operation

• Adjust the appropriate changeover switches to the following settings:

TIG

MMA

When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation. The Up- and Down-slopes are switched off.

start

AMP

1. 2.

Down

end

Fig. 3/4: Function sequence of TIG non-latched operation

1st step:

• Press and hold torch trigger 1.

• The gas pre-flow time passes.

• HF ignition pulses jump from the electrode to the workpiece, the arc ignites.

• The welding current flows and immediately assumes the value set for the ignition current I

start

• HF is switched off.

• The welding current increases in the adjusted Up-slope time to the main current AMP.

2nd step:

• Release torch trigger 1.

• The main current falls in the adjusted Down-slope time to the end-crater current I

end

(minimum

current).

• The main current reaches the end-crater current I

end

, the arc extinguishes.

• The gas post-flow time set passes.

If the 1st torch trigger is pressed during the Down-slope time, the welding current returns to the main current AMP set.

3 Function specification

3/8

3.3.3 TIG latched operation

• Adjust the appropriate changeover switches to the following settings:

TIG

MMA

When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation. The Up- and Down-slopes are switched off.

start

AMP

end

Down

AMP%

1. 2. 3. 4.

Fig. 3/5: TIG latched function sequence

Step 1

• Press torch trigger 1, the gas pre-flow time passes.

• HF ignition pulses jump from the electrode to the workpiece, the arc ignites.

• Welding current flows and immediately assumes the ignition current value set (search arc at

minimum setting). HF is switched off.

Step 2

• Release torch trigger 1.

• The welding current increases in the adjusted Up-slope time to the main current AMP.

(Secondary current AMP% see Chap. 3.1)

Changeover from the main current AMP to the secondary current AMP%:

• Press torch trigger 2 or

• Tap torch trigger 1 (tapping mode see also Chap. 3.2.4)

Step 3

• Press torch trigger 1.

• The main current falls in the adjusted Down-slope time to the end-crater current I

end

(minimum

current).

step

• Release torch trigger 1, the arc extinguishes.

• The gas post-flow time set begins.

Immediate termination of the welding procedure without Down-slope and end-crater current:

• Briefly press the 1st torch trigger (3rd and 4th step).

The current falls to zero and the gas post-flow time begins.

3 Function specification

3/9

3.4 TIG pulses, function sequences

The machines have an integrated TIG pulse device as standard. Entering the pulse parameters:

• Pulse current = main current AMP,

• Break current = secondary current AMP%.

The times for the pulse and break current are pre-set at 0.3 sec ex works and can be changed internally (see Chap. 3.9.5)

TIG pulses can also be realized with the pulse remote controls RTP1 and RTP2. The function sequences of TIG pulses are principally the same as for standard TIG welding.

As soon as the arc has ignited, the current switches to and from between the pulse current and pause current with particular times.

When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation. The Up- and Down-slopes are switched off.

See the explanation of symbols under Chap. 3.3.1.

3.4.1 TIG pulses - non-latched operation

• Adjust the appropriate changeover switches to the following settings:

TIG

MMA

AMP%

start

AMP

end

Down

1. 2.

Fig. 3/6: TIG pulses non-latched function sequence

3 Function specification

3/10

3.4.2 TIG pulses - latched operation

• Adjust the appropriate changeover switches to the following settings:

TIG

MMA

start

AMP

end

Down

AMP%

1. 2. 3. 4.

Fig. 3/7: TIG latched function sequence

3.5 MMA welding

Therefore, always place the torch and the electrode holder on an insulated surface before starting work and during breaks.

• Adjust the appropriate changeover switches to the following settings:

TIG

MMA

This machine has the following features in electrode operation: Arcforcing

Shortly before the electrode threatens to stick, the arcforcing device sets an increased current designed to impede sticking of the electrode. The value of the current increase depends on the arcforce setting. Excellent welding properties are achieved with all difficult electrodes by adjustable arcforcing.

Hotstart The hotstart device has the effect of better ignition of the stick electrodes by an increased ignition

current. 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 overheating of the electrode is prevented. If the antistick device has responded, check the main current setting and if necessary correct it.

3.5.1 TRITON 260 adjustable arcforcing

Two arcforcing settings can be selected on the characteristics changeover switch (Chap. 2, G2) on the rear of the machine:

• Characteristics 1: BASIC (welding with stick electrodes enveloped with basic

material),

• Characteristics 2: RUTILE (welding with stick electrodes enveloped with rutile),

3 Function specification

3/11

3.5.2 TRITON 400/500 adjustable arcforcing

Adjustment at 8 levels is possible before and during the welding operation.

Settings are made on the inner scale: "Rutile" setting:: Low arcforcing ⇒ gentle arc, little increased current before short-circuit. Used with stick electrodes enveloped with rutile. "Bas" setting: Moderate arcforcing ⇒ normal arc, moderate increased current before short-circuit. Used with stick electrodes enveloped with basic material. "Cell" setting: High arcforcing ⇒ hard arc, high increased current before short-circuit. Used with cellulose stick electrodes.

3.6 MIG/MAG welding (Option)

Therefore, always place the torch and the electrode holder on an insulated surface before starting work and during breaks.

• To be able to use the MIG/MAG welding process, a wire feed unit must be connected.

The MIG/MAG function sequences are described in the operating instructions of the wire feed unit.

• Adjust the appropriate changeover switches to the following settings:

GMAW

MIG/MAG

• Adjust further settings on the WF unit.

3.6.1 TRITON 260

In MIG/MAG welding, only the following operating and display elements on the welding machine are active:

• The digital display,

• the welding voltage or current changeover switch display (C1),

• the characteristics changeover switch (Chap. 2, G2) on the rear of the welding machine:

Characteristics 1: 0.8-1.0 MIG/MAG GMAW (welding with steel wire), Characteristics 2: 0.9-1.2 FCAW (welding with cored wire),

• Rotary switch Dynamic correction / choke effect setting.

3 Function specification

3/12

3.6.2 TRITON 400/500

In MIG/MAG welding, only the following operating and display elements on the welding machine are active:

• The digital display (D1),

• the welding voltage or current changeover switch display (C1),

• the roatry dial characteristic line (B3),

• Rotary switch Dynamic correction / choke effect setting.

8 permanently programmed characteristic lines are stored for MIG/MAG welding. These can be called up in 8 levels. The type of material, wire diameter and type of gas are stored in one characteristic line. Setting is with the aid of the outer scale and can be done before the welding operation.

Characteri-

stic line number

Material Wire

diameter (mm)

Type of gas

FCAW (cored wire)

0.9 – 1.2

G3/4Si1 (low-alloy steel)

0.8 – 1.0

Ar/Mix

G3/4Si1 (low-alloy steel)

1.2 – 1.6

Ar/Mix

G3/4Si1 (low-alloy steel)

0.8 – 1.0

100%

G3/4Si1 (low-alloy steel)

1.2 – 1.6

100%

CrNi (high-alloy steel)

0.8

various

CrNi (high-alloy steel)

1.0 – 1.6

various

Al/Cu (aluminium or copper alloys)

1.0 – 1.6

Ar 100%

3 Function specification

3/13

3.7 Remote control

Only the remote controls described in these operating instructions should be connected. Plug in and lock the remote control to the remote control connection socket only, and only when the welding machine is switched off (chap. 2.1.1, G1 for TRITON 260 and chap. 2.2.1, G3 for TRITON 400/500). The remote control must never be connected to a wire feed unit. See the operating instructions for the remote control for more detailed information.

Foot-operated remote control RTF 1 Manual remote control RT1

Functions:

• Welding current "ON/OFF" (switches on after the pedal has been pressed).

• Infinitely adjustable welding current (in %) depending on the preselected main current or I

of the welding

machine.

Functions:

• Infinitely adjustable welding

current (in %) depending on the welding current I

preselected on the welding machine.

When the foot-operated remote control RTF 1 is connected, the machine switches automatically to non latched operation. Up- and Down-Slope will be switched off.

RTP 1 manual remote control RTP 2 manual remote control

RT P 1

t1t

I1I

I2I

t1t

t2t

100250

100

t (sek)2t (sek)

0,05

0,5

1,5

t (sek)1t (sek)

x10

0,05

0,5

1,5

I1I

I2I

I1I

(%AMP)

(% I )

I2I

Functions:

• TIG / MMA

• Pulse / spot / normal

• The percentage settings

of the main and secondary current depending on the preselected welding current I

of the welding

machine.

• Pulse, spot and break

times are infinitely adjustable.

RT P 2

t1t

I1I

100250

100

2,5

7,5

12,5 15

sec

x10 x100

x0,1x1x0,1

17,5

22,5

Balance%Balance

250-2500

0,25-2,5

25-250

2,5-25

Hz / secHz /

1I1

I2I

I1I

I2I

I1I

(% AMP)

(% I )

I2I

Functions:

• TIG / MMA

• Pulse / spot / normal

• The percentage settings of

the main and secondary current depending on the preselected welding current I

of the welding machine.

• Frequency and spot times infinitely adjustable.

• Coarse adjustment of the cycle frequency.

• Pulse/break ratio (balance) adjustable from 10% to 90%.

• For remote controls RTP 1 and RTP 2, adjust the following settings on the appropriate changeover switch:

TIG

MMA

3 Function specification

3/14

3.8 TIG interface for mechanised welding (remote control connection socket)

The welding current sources feature a very high standard of safety. This safety standard is also retained when peripheral equipment is connected for automatic welding if this peripheral equipment fulfils the same criteria, particularly with regard to their isolation from the mains supply.

This is ensured by the use of transformers according to VDE 0551. The welding machines are equipped for automated operation as standard.

For automated applications, control inputs and a galvanically isolated relay contact are avail ab le at the remote control connection socket (TRITON 260; Chap. 2, G1); TRITON 400/500; Cha p. 2,

G3). Interface for mechanised welding 19 pole connection socket (TRITON 260; Chap.2, G1); TRITON 400/500; Chap. 2, G3):

• Pin A Output: Connection for cable screen.

• Pin B/L Output: Current relay contact (I>0) to the user (galvanically isolated)

maximum load +/- 15 V / 100 mA.

• Pin F Output: Potentiometer reference voltage 10 V, max. 10 mA.

• Pin K Output: Power supply +15 V, max. 75 mA.

• Pin V Output: Power supply -15V V, max. 25mA mA.

• Pin C Input: Nominal value for main current, 0-10V (0V = I

min

, 10V = I

max

)

• Pin D Input: Nominal value for secondary current, 0-10V (0V = I

min

, 10V = I

max

• Pin J/U Output: 0V

• Pin R Input: Start / stop.

• Pin H Input: Switching between main and secondary current.

• Pin S Input: Switching between MMA and TIG operation.

• Pin M/N/P Input: Nominal value identification.

• Pin G Output: I

nominal

0-10V

Cable screenCable screen

10V/max.10mA

A B L F

D E T

M N P

I>0I > 0

Nc Nc 0V

+15V/75mA

-15V/25mA Start/Stop Tig / MMATig

/ MMA

Pulser I / I

Pulser I/I

FR-Typ1 FR-Typ2 FR-Typ3

NOMINAL

Start Stop MMA / TIG

Secondary Current I

Secondary Current

L H

Main Current I

Main Current

10k10k

Nominal Value Identification.

Nominal

Value

Identification.

Nominal value identification.Nominal

value identification.

External Nominal Values

For

Main Current Active

External Nominal Values

For

Main

Current Active

External Nominal Values For Main Current

0-10V

External Nominal Values For Main

Current 0-10V

External Nominal Values For Secondary Current

0-10V

External Nominal Values For Secondary

Current 0-10V

External Nominal Value For Main

And

Secondery Current Active

External Nominal Value For

Main And

Secondery

Current Active

Fig. 3/8: Interface for mechanised welding, 19-pole

3 Function specification

3/15

3.9 Welding parameter adjustments "internally"

The welding parameters are preadjusted to optimum settings for most applications, changes are only necessary for special applications. The welding parameters can be changed on the T101 circuit board in the welding machine.

Explanation of symbols

Symbol Meaning



Jumper open

Jumper closed

Turn trimmer to the right

Turn trimmer to the left

Bestückungsdruck (044-442395-00002)

IWIGmax

IELmax

tPause

tPuls

Istart

tUP

Frontplatte

Dynamikerw.Dynamik-Schalter

V/A-Meter

Brenner

Dynamik

MIG ein/aus

Peripherie

Erw.

Fernreg.

Prog.

Inv.Steuersatz

EWM

T101

V53

C98

C97

C96

C95

C94

C93

C92

C91

C90

C89

C88

C87

C86

C85

C84

P10

V70

V43

D17

D14

C83

C82

R214

R213 R212

JP7

R211

S4 S3

R210

R209R208

V69

V68

V67

V66V65

V64

V63V62

V61

JP10

JP18

V60

V59

R207

JP17

V58

V57

R206

R205

C81

R204

V56

D21

V55

R203 C80

R201

R199

R198

P11

P12

R195

R194

R193

C79

R191

R190

V52

C78

C77

R189 R188

R187

C76

C75

R186

X12

2431

X10

X11

R185

D20

R184

V51

V50

R183

R182

C74

R181

R180

C73

R179

D19

C72

JP16

V49

V48

V47

R178

V46

V45

R177

R176

R175

C71

C70 C69

D18

C68

C67

JP14

JP15

R174

C66

R173

R172

D16

C65

R171

R170

R169

V44

C64

R168

R167

R166

C63

R165

R164

R163

V42

C62

R162

R161

R160

V41

D15

C61

R159

R158

R157

V40

V39

R156

R155

R154

C60

R153

V38

JP13 1

R152

R151

R150

C59

L10

L8L7

C58

C57

C56

C55

RX6

RX5

RX4

RX3

C54

C53

RX2

RX1

C52

V37

C51

R148R146

R145

V36

R139

R138

C50

R137

R136

V35

R135

V34

C49

R134

V33

V32

V31

R133

R132

R131

R130

V30

C48

R129

R128

R127

V29

C47

R126

R125

R124

V28

C46

R123

R122

R121

V27

C45

R120

R119

R118

D13

V26

C44

R117

R116

R115

V25

C43

R114

R113

R112

V24

C42

R111

R110

R109

D12

V23

R108

C41

R107

R106

V22

R105

R104

V21

C40

R103

JP5

V20

V19

R102

R101

V18

R100

R99

R98

R97

V15

V17

V16

R96

R95

C39C38

C37

D11

R94

D10

R93

R92R91

C36

R90

R89R88

C35

R87

R86

R85

C34

R84

R83

R82

C33

R81

C32

R80

R79

R78

R77

R76

V14

C31

LED2

R74

R73

V13

R71

R70

R69

V12

JP12

C30

R68

R67

R66

R65

R64

R63

R62

R61

R60

R59

R58

C29

Q2 C28

V11

C27

R57

R56

C26

R55

R54

R53

R52

C25

C24

C23

R51

V10

C22

R50

JP11

R49

R48

C21

C20

C19

C18

R47

R46

R45

R44

R43

R42

C17

R41

R40

R38

R37

R36

R35

R34

R33

R32

R31

R30

C10

C11

C12

C14

C15

C13

C16

LED1

R18

R10

R11

R12

R13

R14

R15

R16

R17

R21

R22

R24

R25R26

R27

P10

S3 tPuls

S4 tPause

JP16

JP5

P2 tUP

JP15

JP14

JP13

P1 Istart

Fig. 3/9: T101 screen printed PCB

3.9.1 P10: Gas pre-flow time

The gas pre-flow time is infinitely adjustable from 0 to 5 sec (works setting 0.2 sec).

Function Setting

Increase gas pre-flow time

Reduce gas pre-flow time

3 Function specification

3/16

3.9.2 P1 I-start: Ignition current

The ignition current is infinitely adjustable from 0% to 100% of the main current AMP (G1) (works setting 30%)

Function Setting

Increase ignition current

Reduce ignition current

(search arc in 0% position)

3.9.3 P2 t-UP: Up-slope time

Current increase from the ignition current I

start

to the value of the main current AMP (G1) infinitely

adjustable from 0 to 5 sec (works setting 0.1 sec).

Function Setting

Increase Up-slope time

Reduce Up-slope time

3.9.4 JP5: Switching between normal or tapping operation

(works setting tapping operation)

Operating mode configuration Setting

Tapping released : JP5 Tapping blocked  JP5

3.9.5 S3 tPulse and S4 tPause: TIG pulses, pulse and break time adjustment

Switch position

0/1 2/3 4/5 6/7 8/9

A/B C/D E/F

Time [sec]

0.1 0.3 0.5 0.7 0.9 1.1 1.3 1.5

Table 1: Coding switch

3.9.5.1 S3 tPulse: Pulse time (works setting 0.3 sec)

The pulse time can be adjusted from 0.1 sec to 1.5 sec in 0.2 sec steps on coding switch S3 (see table 1)

3.9.5.2 S4 tPause: Pulse break (works setting 0.3 sec)

The pulse break can be adjusted from 0.1 sec to 1.5 sec in 0.2 sec steps on coding switch S4 (see table 1)

3.9.5.3 Example of settings for the pulse time and pulse break

Requirement: The pulse time should be 1.1 sec and the break time 0.5 sec:

• Coding switch S3 must be switched to position A or B,

• Coding switch S4 must be switched to position 4 or 5,

3 Function specification

3/17

3.10 Programming of the torch operation variants

The user can select the following functions (TT=torch trigger):

• Operating modes standard TIG welding torch with 5-pole connector plug

Mode1: Operation with standard TIG torch, welding current on/off, no Up/Down function (MG rocker or separate TT) Mode2: Up-Down operation with standard TIG torch (MG rocker) Mode3: Up-Down operation with standard TIG torch (2 separate TT)

• Changing Up-Down speed. The function is selected with the torch triggers on the welding torch

(does not apply to standard TIG torches with one TT, see also Chap. 3.10.4).

3.10.1 Mode1, standard operation (works setting) with standard TIG torch

Design: 2 trigger

Symbol Functions Operation with

Welding current On/Off TT 1 secondary current TT 2 secondary current TT 1 in tapping mode

Design: (MG rocker)

Welding current On/Off TT 1 (rocker forwards) secondary current TT 2 (rocker back)

secondary current TT 1 (rocker forwards)

in tapping mode

Programming Mode1:

• Switch off the machine and wait approx. 3 sec.

• Set the main current rotary dial (G1) to maximum.

• Press and hold torch triggers 1 and 2 at the same time.

• Switch on the machine Î Display (D1) indicates maximum current.

• Release both torch triggersÎ Display (D1) indicates minimum current.

• Torch trigger 2: press 1x.

• Press torch trigger 1 Î the mode is stored in the memory Î the half-maximum current is

displayed.

• Switch off the machine, wait approx. 3 sec and switch on again Î machine ready in mode 1.

3.10.2 Mode 2, Up/Down operation for standard torches with a rocker

Design: 2 triggers (MG rocker)

Symbol Functions Operation with

Welding current On/Off TT 1+2 simultaneously UP function: TT 1 (rocker forwards) Down function: TT 2 (rocker back) secondary current TT 1+2

in tapping mode

Programming Mode2:

• Switch off the machine and wait approx. 3 sec.

• Set the main current rotary dial (G1) to maximum.

• Press and hold torch triggers 1 and 2 at the same time.

• Switch on the machine Î Display (D1) indicates maximum current.

• Release both torch triggersÎ Display (D1) indicates minimum current.

• Press torch trigger 2 2x.

• Press torch trigger 1 Î the mode is stored in the memory Î the half-maximum current is

displayed.

• Switch off the machine, wait approx. 3 sec and switch on again Î machine ready in mode 2.

3 Function specification

3/18

3.10.3 Mode 3, Up/Down operation for standard torches with two triggers

Design: 2 trigger

Symbol Functions Operation with

Welding current On/Off TT 1 secondary current TT 1 in tapping mode Up/Down function Down = press and hold Up = tap and hold

TT 2

Programming Mode3:

• Switch off the machine and wait approx. 3 sec.

• Set the main current rotary dial (G1) to maximum.

• Press and hold torch triggers 1 and 2 at the same time.

• Switch on the machine Î Display (D1) indicates maximum current.

• Release both torch triggersÎ Display (D1) indicates minimum current.

• Press torch trigger 2 3x

• Press torch trigger 1 Î the mode is stored in the memory Î the half-maximum current is

displayed.

• Switch off the machine, wait approx. 3 sec and switch on again Î machine ready in mode 3.

3.10.4 Setting the Up/Down speed

This adjustment applies both to the standard TIG torches (5-pole), and to the Up/Down torches (8-pole).

It is possible to select 3 changing speeds of the Up-Down function:

• Up-Down speed=1 (rapid current changing speed)

• Up-Down speed=2 (moderate current changing speed)

• Up-Down speed=3 (slow current changing speed)

Programming Up/Down speed:

• Switch off the machine and wait approx. 5 sec.

• Set the main current rotary dial (G1) to maximum.

• Press and hold torch triggers 1 and 2 at the same time.

• Switch on the machine Î Display (D1) indicates maximum current.

• Release both torch triggersÎ Display (D1) indicates minimum current.

• Press torch trigger 1 1 to 3x, depending on the Up/Down speed required.

• Press torch trigger 2 Î the mode is stored in the memory Î the maximum current is displayed.

• Switch machine off and on again Î programmed Up/Down speed is programmed.

3.11 Returning the machine to the works settings

Necessary if the machine has been changed to Up/Down function but no standard TIG torch with a trigger is available at the moment.

Switch off machine > plug in jumper JP16 > switch on machine > switch off machine > remove jumper JP16.

After resetting the machine, it has the works settings with the following values:

• Up-Down value at maximum (100% of AMP)

• Up-Down mode = 1 (i.e. Up-Down function for standard TIG torches is switched off)

• Up-Down speed = 2 (i.e. moderate current changing speed)

3 Function specification

3/19

3.12 JP13, JP14 and JP15: Configure welding torch connection

When connecting a potentiometer torch, the following jumpers must be change d inside the welding machine (see fig. 3.9):

Welding torch configuration Setting

Prepared for TIG standard or Up-Down torch (works setting) : JP13  JP14 : JP15 Prepared for potentiometer torches  JP13 : JP14  JP1 5

3 Function specification

3/20

3.13 TRITON 400/500 interface for mechanised MIG/MAG welding (option)

This is ensured by the use of transformers according to VDE 0551. The welding machines are equipped for automated operation as standard.

For automated applications, control inputs and galvanically isolated relay contacts are available on the machine connection sockets.

Use only shielded control leads!

Interface for mechanised welding

Pin Input / Output Designation A

Output Connection for cable screen

B Output +Iactual (10V = 1000A welding current) C Input Interface for mechanised welding ON (relay with 0V) D/E/F Input Selection of welding process* G/S Output 0V H Output Power supply +15 V, max. 75 mA J/U Input Fixed-wire L Output +Uactual (10V = 100V welding voltage) M Input UnominalAU

(2V to 10V = 10V to 50V welding voltage)

N Input Nominal value input for WF, 0-10V

(0V = 0.5m/min, 10V = 24m/min wire feed speed)

P Input Start signal of machine (relay with 0V) R Output Reference voltage 10 V, max. 10 mA. T Output Power supply -15V , max. 25mA V Output Current relay contact (I>0) to the user (galvanically isolated)

maximum load +-15V / 100 mA

Interface for mechanised

welding, Pin

*Selection of welding characteristic line (see Chap. 3.6.2)

D E F

10V 10V 10V

2 0V 10V 10V 3 10V 0V 10V 4 0V 10V 10V 5 10V 10V 0V 6 0V 10V 0V 7 10V 0V 0V 8 0V 0V 0V

Dynamik 3Dynamik 3

AutoEin

+Iist

Usoll AUUsoll

Uist

Drahtfest

-15V1

0V1

Uref

10VUref.

10V

0V1

IGR0 R

elaisIGR0

Relais

DVsoll

Start/Auto

IGR0 R

elaisIGR0

Relais

+15V1

Dynamik 1Dynamik

Dynamik 2Dynamik

19pol. Buchse19pol. Buchse

2n2F

Fig. 3/6: Interface for mechanised

welding, 19-pole

4 Quick start – the fastest way to weld

4/1

Preparations Settings Settings and troubleshooting

• Plug in the mains plug. (Remember fuse protection!)

• Set the welding process

Arcforce

• Select arcforcing (only applies to MMA applications and TRITON 400, 500)

• Plug in the workpiece lead, lock and attach conductively to the workpiece.

Puls

• Select TIG pulses or standard TIG welding

• Set the ignition mode:

HF ignition

Liftarc (contact ignition)

• Insert the welding current plug of the torch

• Select the operating mode.

Excess temperature LED on:

• Duty cycle exceeded > Allow machine to cool down

• Connect torch trigger plug.

AMP

• Select main current

Water deficiency LED:

• When operating water cooled welding machines with a cooling module, the Water Deficiency LED will be active.

• Establish the shielding gas supply, adjust the gas flow

AMP %

0 100

• Select secondary current (in % of main current)

Collective interference LED:

•

Power unit is switched off. Some

errors are short-term, one-off errors and the collective interference signal light goes off again and the welding machine is read

for welding again.

• Plug in the remote control connection plug

5 15

• Select gas post-flow time (1 – 20sec.)

• Switch on machine at the main switch

5 15

• Select down-slope time (0 – 20sec.)

5 Commissioning

5/1

5.1 Area of application

5.1.1 Designed use

These welding machines are suitable exclusively for TIG, MMA and MIG/MAG welding. Any other use is regarded as "not as designed", 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 delive ry programme!

5.1.2 Triton 260

• MMA directff current welding for rutile and basic coated electrodes.

• TIG direct current welding with HF ignition or Liftarc for

low- and high-alloy steels, copper, nickel-based alloys and special metals.

• MIG/MAG welding in combination with an additional wire feed unit (optional) for steel-CrNi ∅ 0.8mm-1.0mm, aluminium ∅ 1.0mm-1.2mm and cored wires ∅ 0.9mm-1.2mm.

5.1.3 Triton 400/500

• MMA direct current welding for rutile, basic and cellulose electrodes.

• TIG direct current welding with HF ignition or Liftarc for

low- and high-alloy steels, copper, nickel-based alloys and special metals.

• MIG/MAG welding in combination with an additional wire feed unit (optional) for steel-CrNi ∅ 0.8mm to 1.6mm, aluminium ∅ 1.0mm to 1.6mm and cored wires ∅ 0.9mm to 1.2mm.

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

5.3 Mains connection

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

regulations. The phase sequence is irrelevant and has no effect on the direction of rotation of the fan!

The operating voltage shown on the rating plate must be consistent with the mains voltage! For mains fuse protection, please refer to the technical data (chapter 3)!

• Insert mains plug of the switched-off machine into the appropriate socket.

5.3.1 Reconnecting the mains voltage 400/415V and 440/460V

The plug on the NEF4 must be changed over according to the mains voltage. The PCB NEF4 is located inside of the machine on the left side.

• For 400/415V: Plug to pos. A

(works setting)

• For 440/460V: Plug to pos. B

5 Commissioning

5/2

5.4 Welding machine cooling system

To obtain an optimal duty cycle from the power components, the following precautions should be observed:

• Ensure that the working area is adequately ventilated,

• Do not obstruct the air inlets and outlets of the machine,

• Metal parts, dust or other foreign bodies must be kept out of the machine.

5.5 Workpiece lead, general

Remove paint, rust and dirt from clamping and welding areas with a wire brush! The workpiece clamp must be mounted near the welding point and must be fixed in such a way that it cannot come loose of its own accord.

Structural parts, pipes, rails etc. may not be used as return leads for the welding current unless they are the workpiece themselves! A perfect current connection must be ensured where welding benches and appliances are concerned!

5.6 Connection groups

Therefore, always place the torch and the electrode holder on an insulated surface before starting work and during breaks.

E1 F1

B1 C1

Fig. 5/1 Group of connections on the front of the

machine TRITON 260

Fig. 5/3 Group of connections on the front of the

machine TRITON 400/500

F2 E2

D2 C2

Fig. 5/2 Group of connections on the rear of the

machine TRITON 260

Fig. 5/4 Group of connections on the rear of the

machine TRITON 400/500

5 Commissioning

5/3

5.7 MMA welding

When replacing spent or new stick electrodes, always switch off the machine at the main switch.

Always use insulated tongs to remove used stick electrodes or to move welded workpieces. Always put the electrode holder down when insulated.

5.7.1 Electrode holder

• Insert cable plug of the electrode holder into the welding current socket (C1 "+" or D1 "-") and lock by turning to the right.

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

Clamp stick electrode into electrode holder. Caution: Risk of injury from crushing! Always put down stick electrode holder in an insulated position.

5.7.2 Workpiece lead

• Insert cable plug of the workpiece lead into the welding current socket (C1 "+" or D1 "-") and lock by turning to the right.

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

5.8 TIG welding

We can only guarantee the perfect functioning of our machines when used with our range of welding torches.

Standard TIG welding torches with shielded torch trigger control leads should not be connected (see torch operation instructions)!

Follow the safety instructions on the opening pages entitled "For your safety". Before welding ensure that all coolant hoses are connected.

5.8.1 Welding torch, general

Always put down welding torch when insulated.

• Fit tungsten electrode and gas nozzle onto the welding torch (observe current load, see torch operating instructions).

• Engage the rapid-action closure nipple of the TIG torch in the rapid-action closure coupling for the coolant supply (blue) and return (red) lines of the cooling unit (only for water-cooled torches).

• If a gas-cooled torch is used on a water cooled unit, either a tube bridge must be connected between the water supply and the cooling unit return to prevent the coolant pump from running hot, or the control lead of the cooling unit must be removed from the welding machine.

• Insert the welding current plug into socket "-" (E1) and lock by turning to the right.

• Screw shielding gas connection of the welding torch tightly on to the connection nipple G¼ (F1

5 Commissioning

5/4

5.8.1.1 Standard TIG torch

• Insert the torch control lead plug (5-pole) into the connection socket (A1) and lock.

The welding machines are supplied as standard with torch trigger pin assignment B1 and gas connection G1/4".

3 2

Fig. 5/5: Connection socket connection B1

5.8.1.2 TIG Up/Down or TIG potentiometer welding torch Potentiometer torches available on the market e.g. from Binzel can be used.

• Insert the torch control lead plug (8-pole) into the connection socket (B1) and lock.

Fig. 5/6 Connection socket assignments

Up/Down torch

Uref 10VUref 10V

IH-Down

Poti UD/einPoti

UD/ein

E F

10k

C D

BT1 BT2

A B

Fig. 5/7: Connection socket assignments

Potentiometer torch

5.8.2 Shielding gas supply (shielding gas cylinder to the welding machine)

No impurities must be allowed to enter the shielding gas supply as these could cause blockages in the shielding gas supply.

• Place shielding gas cylinder in the retainer provided for it and secure with chains.

• Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to

blow out any dirt present.

• Screw the pressure reducer onto the cylinder valve, ensuring a gas-tight connection.

• Connect the pressure reducer to the G¼ shielding gas connection (F1) on the rear of the

machine.

• Open gas cylinder valve and set recommended gas quantity on the pressure reducer.

Rule of thumb for gas flow rate: Diameter of gas nozzle in mm corresponds to gas flow in l/min.

Example: 7 mm gas nozzle corresponds to 7 l/min gas flow

5.8.3 Workpiece lead

• Insert cable plug of the workpiece lead into the welding current socket (C1) and lock by turning

to the right.

5 Commissioning

5/5

5.9 MIG/MAG welding (option)

Simultaneous TIG and MIG/MAG welding is not possible

5.9.1 TRITON 260

Always put down welding torch when insulated. In MIG/MAG welding, only the following operating and display elements on the welding

machine are active:

• Digital display (chap.3, D1),

• Welding voltage / welding current display changeover switch (chap.3, C1),

• Characteristics changeover switch (chap. 2, G2) on the rear of the welding machine:

Characteristic 1: 0.8-1.0 MIG/MAG GMAW (welding with steel wire), Characteristic 2: 0.9-1.2 FCAW (welding with solid/cored wire) and

• Dynamic correction / choke effect rotary switch (chap.3, B2).

5.9.1.1 Supply to the wire feed unit

• Insert the welding current plug of the WF unit in the welding current socket (C1 "+") and lock by

turning to the right.

For special MIG/MAG applications such as welding cored wires for example, the WF unit welding current plug is plugged into the "-" socket (E1) and locked by turning to the right.

• Insert the control lead plug (7-pole) into the connection socket (G2) and lock (rear of machine).

• Please see the wire feed unit operating instructions for further information.

5.9.1.2 Workpiece lead

• Insert cable plug of the workpiece lead into the welding current socket (C1 "+" or E1 "-"

depending on the application

) and lock by turning to the right.

5.9.2 TRITON 400/500

In MIG/MAG welding, only the following operating and display elements on the welding machine are active:

• Digital display,

• Welding voltage or current display changeover switch,

• Characteristics rotary dial (chap.3, C3) and

• Dynamic correction / choke effect rotary switch (chap.3, B3).

If only one torch (either TIG torch or MIG/MAG torch) is to be connected (e.g. infrequent changing between processes),

the cooling units COOL 71U40 or COOL 71U41 can be used. In this case, either TIG torches or MIG/MAG torches may be connected.

• With MIG/MAG welding the WF unit should be connected to the cooling unit

• For this application, the coolant supply line (blue) and return line (red) on the cooling unit

should be connected to the coolant supply line (blue) and return line (red) on the WF unit.

5 Commissioning

5/6

If a TIG torch and MIG/MAG torch are to be connected at the same time (e.g. frequent changing between the processes) the more powerful cooling unit COOL 71U41 should be used. Under certain circumstances, limitations in cooling output may arise despite the more powerful cooling unit; e.g. excessively long intermediate hose packages or torches, special torches, etc.

TRITON 400/500

COOL 71U41

blue

red

TIG torch

MIG/MAG

torch

ZWIP

red

WF unit

Fig. 5/8

5.9.2.1 Supply to the wire feed unit

• Insert the welding current plug of the WF unit in the socket (I2 "+") (option) and lock by turning

to the right.

For special MIG/MAG applications such as welding cored wires for example, the WF unit welding current plug is plugged into the "-" socket (H2) (option) and locked by turning to the right.

• Insert the torch control lead plug (7-pole) into the connection socket (G2) and lock (rear of

machine).

• Please see the wire feed unit operating instructions for further information.

5.9.2.2 Workpiece lead

• Insert cable plug of the workpiece lead into the welding current socket (C1 "+" or E1 "-"

depending on the application

) and lock by turning to the right.

5.10 Cooling unit function specification

A function test of the cooling module is performed after the welding machine is switched on. The coolant pump and the fan are switched on.

When the pump is running, the coolant level is sufficient and a sufficient hydrostatic pressure has built up, the cooling module is switched off after 2 seconds.

If the level is not sufficient a coolant error is reported and the pump runs for a maximum of 30 seconds so that the operator can top up the coolant.

The cooling unit is switched on at the start of the TIG or MIG/MAG welding process. After the welding process has stopped, the water pump and fan continue to run for a further 5min and then switch off.

5.10.1 Coolant error

If there is no coolant pressure for longer than 2.5 sec during the welding operation e.g. because of a lack of coolant, pump failure or a burst or leaking hose:

• an error message is issued (LED see fig. 3/1, pos. K1)

• and the welding process is ended in a controlled manner

(coolant pump and power unit of the welding machine are swit ched off).

With renewed starting of the welding process, the coolant error is reset and the cooling module switched on. If still no coolant pressure has built up after 2.5 sec, the cooling module is switched off, the LED coolant level low (see fig. 3/1, pos. K1) lights up and the welding process is ended in a controlled manner.

6 Maintenance and care

6/1

Under normal operating conditions, these welding machines are largely maintenance-free an d 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.

6.1 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 or circuit boards with the

compressed air stream but suck clean using a vacuum cleaner.

6.2 Repetition test according to VDE 0702, VBG 4 and VGB 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 welding current source

• Measurement of open circuit voltage

• Function test of the welding machine

6.2.1 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 cable, e.g. insulation faults, scorch or pressure marks.

• Defects in anti-kink protection and the strain relief of the connecting 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 warning symbol must be present and legible.

6.2.2 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 connecting lead, especially near the connecting points, must be moved. The resistance must be < 0.1Ω. The measurement must be performed using at le ast 200 mA.

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!

6 Maintenance and care

6/2

6.2.3 Measurement of insulation resistance

Disconnect the machine from the mains. Pull out the mains plug! Open the machine and clean carefully (as described above). Switch on mains switch.

• Insulation resistance mains current circuit-casing

Switch on mains switch. 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 MΩ. b) Inverter machines: Measure from one phase of the mains plug to the housing. The resistance must be > 2.5 MΩ.

• Insulation resistance welding current circuit-casing

Measure between a welding socket and protective conductor. The resistance must be > 2.5 MΩ.

• Insulation resistance mains current circuit welding-current circuit

Switch on mains switch. a) Step switch controlled machines: Measure the insulation resistance between the mains fuse output and a welding current socket. The resistance must be > 5 MΩ. b) Inverter machines: Measure between a phase of the mains plug and a welding current socket. The resistance must be > 5.0 MΩ.

6.2.4 Measurement of open circuit voltage (according to EN 60974-1 / VDE 0544 T1)

6u8F

10nF

0...5k

Measurement circuit for peak values

Input

0k2

1k0

Diode similar 1N 4007

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 0kΩ to 5kΩ during the measurement. The measured voltage must not deviate from that specified on the rating plate (U

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

6.2.5 Function test of the welding machine

Carry out a function test depending on the type of machine.

6.3 Repair work

Repair and maintenance work may only be performed by qualified personnel. In all service matters, always consult your dealer, the supplier of the machine.

Return deliveries of defective equipment subject to warranty may only be ma de 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 ar e not trained and authorised to undertake such work, the right to claim under the warranty lapses.

7 Operating faults, causes and remedies

7/1

7.1 Customer checklist (TIG welding)

All machines are subjected to strict manufacturing and final inspection procedure s. If, despite this, something fails to work at any time, please check machine using the following flowcha rt. If none of the fault rectification procedures described leads to the correct functioning of the machine, please inform your authorised dealer.

Switch on machine

(mains switch, chapter 2 B2 and B3)

Yes

Machine functioning

(display is on, chapter 3, D1)

No • Mains plug not inserted

• Mains fuse faulty

• Mains supply interrupted

• Mains power switch faulty

• Mains plug wrongly connected

• Yellow LED (chapter 3, K1) excess temperature

is on (allow machine to cool down)

• Red LED (chapter 3, E1) is on – collective fault

(notify dealer)

Yes

Pump is running (cooling module)

No • Coolant fault (chapter 3, K1) is on:

Check coolant level

Yes

Press torch trigger

Yes

Shielding gas is expelled

No • No shielding gas connected

• Pressure reducer turned off

Yes

HF ignition

No • Torch control cable not inserted

• Ignition type changeover switch is on liftarc (for

switch see chapter 2, F2 and K4) – change to HF ignition

• Torch wrongly connected (check torch cable

according to the circuit diagram)

• Torch or torch trigger faulty

Yes

Welding current flowing

No • Welding torch faulty

• Workpiece lead connected

• Workpiece lead in wrong socket

Yes

Good welding properties

No • Insufficient shielding gas supply

(check that supply lines are not leaking)

• Tungsten electrode dirty - grind

• Shielding gas setting incorrect

(too little or too much shielding gas)

• Welding torch damaged

Yes

Remote control functioning

No • Remote control not plugged in

• Connection cable faulty

8 Ersatzteilliste / spare part list

8/1

8.1 TRITON 260

A1 B1

C1 D1

E1 F1

G1 H1

O1 P1

TRITON 260 Abb. 8/1 front view / Fig. 8/1 Vorderseite

Pos Bezeichnung

Description

Art. Nr. / art. no.

A1 + R1

(Option)

Gehäusedeckel Casing panel 094-007490-00001

Kippschalter Toggle switch 044-001939-00000

PCB Verbindungsplatine DVM1/2

PCB connection DVM1/2 040-000449-00000

Drehknopf Rotary dial 074-000235-00000 Drehknopfdeckel Rotary dial cap 074-000235-00001 Drehknopf Pfeilscheibe Rotary dial arrow indicator 074-000235-00002 E1

Anschlußbuchse 5 polig Connection socket 5 pole 094-007570-00000 F1

Seitenblech links Side panel 094-007538-00002 G1

Anschlußbuchse 8 polig Connection socket 8 pole 094-006904-00000 H1

Anschlußbuchse Connection socket 074-000232-00000 I1

Gummifüße Rubber foot 094-001718-00000 J1

T101 komplett T101 complete 040-000590-00000

Drehknopf 16mm Rotary dial 16mm 094-000131-00000

Drehknopfdeckel 16mm Rotary dial cap 16mm 094-000131-00001

K1 + Q1

(Option)

Drehknopf Pfeilscheibe 16mm Rotary dial arrow indicator 16mm 094-000131-00002 L1

Anschlußbuchse 19-polig Connection socket 19 pole 094-007651-00000 M1

Seiteblech rechts Side panel 094-007538-00002 N1

Anschlußnippel G1/4 Connection nipple G1/4 094-002695-00001 Isolierstück Insulation piece 094-000075-00000 Druckscheibe Pressure washer 094-000076-00000 Mutter M20 Nut M20 094-000068-00000 Fächerscheibe Fan-type lock washer 094-006516-00000 O1

Griffstange Hand grip 094-007501-00002 P1

Halterung für Griffstange Hand grip mount 094-007383-00003

8 Ersatzteilliste / spare part list

8/2

D2 E2

G2 H2

TRITON 260

Abb. 8/2 Rückseite / Fig. 8/2 rear view

Pos Bezeichnung

Description

Artikelnummer

Hauptschalter Mains switch 074-000279-00001

Kabelverschraubung Screwed cable gland 094-003293-00000 Mutter Nut 024-000205-00001 C2

Netzkabel Mains cable 092-000661-00000 D2

Anschlußbuchse 8polig Connection socket 8-pole 094-006904-00000 E2

PCB Verbindungsplatine

VP 12/D

PCB connection VP 12/D

040-000588-00000

Magnetventil Solenoid valve 094-000472-00001 G2

Kippschalter Toggle switch 094-001898-00000 H2

Anbaugehäuse Extension housing 094-006861-00000 Kappe Abdeck Cap 094-006862-00000 Buchseneinsatz Socket insert 094-006859-00000

A3 B3

TRITON 260

Abb. 8/3 / Fig 8/3

Pos Bezeichnung

Description

Artikelnummer

PCB Steuerelektronik TRDC 4 PCB control electronicsTRDC 4 040-000581-00000 B3

Versorgungstrafo Supply transformer 094-007547-00001 C3

PCB Schweißelektronik T101/1 PCB welding electronic T101/1 040-000539-00001

8 Ersatzteilliste / spare part list

8/3

D4 E4

TRITON 260

Abb. 8/4 linke Seite / Fig. 8/4 left side

Pos Bezeichnung

Description

Artikelnummer

Zündgerät Ignition unit 040-000546-00001 B4

PCB Sperrwandler SPW 6 PCB blocking converter SPW 6 040-000556-00000 C4

Multidul IGBT Multidul IGBT 080-000306-00000 D4

Sicherung 1,6A 2x Fuse 1,6A 2x 044-001744-00000 E4

PCB Schweißelektronik DC 260 PCB welding electronics DC 260 040-000583-00000 F4

Thyristormodul Thyristor module 064-000083-00014 G4

Lüfter Fan 074-000015-00000 H4

Eingangsbrücke Input bridge 064-000844-00016 I4

PCB T100/2 PCB T100/2 042-000498-00000

E5 F5

TRITON 260

Abb. 8/5 rechte Seite / Fig. 8/5 right side

Pos Bezeichnung

Description

Artikelnummer

PCB Schutzbeschaltung DSB 7 PCB protective wiring DSB 7 040-000589-00000 B5

Sekundärdioden 4x Secondary diodes 4x 044-002601-00000 C5

Thermoschalter Thermal switch 064-000165-00001 D5

Brennertasterfilter Torch trigger filter 040-000545-00000 E5

Lemwandler LEM converter 074-000112-00000 F5

Sättigungswandler Saturation transformer 072-000476-00000 G5

Stromerfassung komplett Current recording complete 072-000501-00000

8 Ersatzteilliste / spare part list

8/4

8.2 TRITON 400/500

A6 B6

D6 E6 F6

M6 N6

Abb. 8/6 TRITON 400/500 Vorderseite;

Fig. 8/6 TRITON 400/500 front view

8 Ersatzteilliste / spare part list

8/5

Pos Bezeichnung

Description

Art. Nr. / art. no.

Griffstange Hand Grip 094-007501-00001

Halterung für Griffstange Hand Grip Mount 094-007383-00003

Gehäusedeckel Casing Panel 094-006540-00005

Steuerschalter Control Switch 094-000525-00000

Schaltergriff Switch Knob 094-001814-00000

PCB Verbindung PCB Connection 040-000449-00000

Pfeilscheibe Arrow Indicator 074-000235-00002

Drehknopfdeckel Knob Cover 074-000235-00001

Drehknopf Knob 074-000235-00000

Gehäuse Seitenblech links Casing side panel 094-007740-00004

Flanschdose Flange Socket 074-000233-00000

Flanschdose Flange Socket 094-006904-00000

Gummifüsse Rubber Foot 074-000223-00000

Kippschalter Toggle Switch 044-001939-00000

T101 Komplett T101 Complete 040-000590-00000

Pfeilscheibe Arrow Indicator 094-000131-00002

Drehknopf Knob 094-000131-00000

Drehknopfdeckel Knob Cover 094-000131-00001

Kabelkonfektion Cable Packaging 094-007651-00000

Mutter M20X1,5 Nut M20X1,5 094-000068-00000

Fächerscheibe Fan-Type Lock Washe r 094-006516-00000

Anschlussnippel Connection Nipple 094-002695-00001

Druckscheibe Pressure Washer 094-000076-00000

Isolierstück Insulation Piece 094-000075-00000

Schweissbuchse Welding Socket 074-000517-00000

Schlauchtülle Tube Bridge 094-000523-00004

Dichtring Kupfer Conical Nipple Cupfer 094-000527-00000

Schnellkupplung Blau Rapid-Action Coupling Blue 094-000521-00000

Gehäuse Seitenblech rechts Casing side panel 094-007744-00004

8 Ersatzteilliste / spare part list

8/6

Abb. 8/7 TRITON 400/500 Rückseite;

Fig. 8/7 TRITON 400/500 rear view

Pos Bezeichnung

Description

Art. Nr. / art. no.

PCB Verbindung PCB Connection 040-000588-00000

Flanschdose Flange Socket 094-006904-00000

Schweissbuchse Welding Socket 074-000517-00000

Schlauchtülle Tube Bridge 094-000523-00004

Schnellkupplung Rot Rapid-Action Coupling Red 094-000520-00000

Dichtring Kupfer Conical Nipple Cupfer 094-000527-00000

Kabelverschraubung Cable Bushing 094-000208-00000

Netzkabel Mains Cable 092-000660-00000

Kippschalter Toggle Switch 044-001939-00000

Abdeckkappe Cap 094-006862-00000

Anbaugehause Extension Housing 094-006861-00000

Buchseneinsatz Socket Insert 094-006859-00000

8 Ersatzteilliste / spare part list

8/7

F8 E8

Abb. 8/8 TRITON 400 linke Seite;

Fig. 8/8 TRITON 400 left side

Pos Bezeichnung

Description

Art. Nr. / art. no.

Lüfter Fan 074-000015-00000

PCB Schweisselektronik PCB Welding Electronics 040-000616-00000

Eingangsbrücke Input Bridge 064-000844-00016

Thyristor-Modul Thyristor-Module 064-000083-00014

Primärschalter Minus (2X) Primary Switch Minus (2X) 080-000301-00000

PCB Sperrwandler PCB Blocking Converter 040-000 556-00000

Primärschalter Plus (2X) Primary Switch Plus (2X) 080-000302-00000

Steuertransformator Control Transformer 094-006803-00004

8 Ersatzteilliste / spare part list

8/8

C9 D9

Abb. 8/9 TRITON 400 rechte Seite;

Fig. 8/9 TRITON 400 right side

Pos Bezeichnung

Description

Art. Nr. / art. no.

PCB Brenner Taster Filter PCB Torch Trigger Filter 040-000545-00000

HF-Coil HF-Coil 040-000586-00000

Sättigungswandler Saturation Transformer 072-000537-00000

Baugruppe Sättigungswandler Componentry Saturation Transf. 072-000476-00000

Sekundärdioden 4X Secondary Diodes 4X 044-002601-00000

PCB Sekundär Beschaltung PCB Secondary Wiring 040-000617-00000

Kondensator Capacitor 092-000500-00005

PCB Steuerelektronik PCB Control Electronics 040-000581-00000

Magnetventil Solenoid Valve 094-000472-00001

PCB Schweisselektronik PCB Welding Electronics 040-000539-00001

Zündgerät Ignition Unit 040-000546-00001

8 Ersatzteilliste / spare part list

8/9

A10

F10

G10

E10

C10

I10

H10

B10

C10 D10

Abb. 8/10 TRITON 500 linke Seite;

Fig. 8/10 TRITON 500 left side

Pos Bezeichnung

Description

Art. Nr. / art. no.

A10

PCB Zwischenkreis PCB Intermediate Circuit 040-000561-00000

B10

PCB Schutzbeschaltung PCB Protective Wiring 042-000705-00000

C10

PCB Zwischenkreis PCB Intermediate Circuit 040-000560-00000

D10

PCB Treiberelektronik 4-Fach PCB Driver Electr. 040-000547-00000

E10

Thyristor-Modul Thyristor-Module 064-000083-00014

E10

Primärschalter Plus (2X) Primary Switch Plus (2X) 080-000302-00000

E10

Primärschalter Minus (2X) Primary Switch Minus (2X) 080-000301-00000

E10

Eingangsbrücke Input Bridge 064-000844-00016

E10

PCB Verdrahtungsplatine PCB 040-000559-00000

F10

Lüfter Fan 074-000267-00000

F10

Lüfter Fan 074-000015-00000

G10

PCB Sperrwandler PCB Blocking Converter 040-000 556-00000

H10

PCB Steuerelektronik PCB Control Electronics 040-000581-00000

I10

Steuertransformator Control Transformer 094-006803-00003

8 Ersatzteilliste / spare part list

8/10

K11

J11

I11

H11

G11

B11

C11

D11 E11

F11

L11

M11

Abb. 8/11 TRITON 500 rechte Seite;

Fig. 8/11 TRITON 500 right side

Pos Bezeichnung

Description

Art. Nr. / art. no.

B11

PCB Potiplatine PCB Poti 042-000498-00000

C11

PCB Brenner Taster Filter PCB Torch Trigger Filter 040-000545-00000

D11

HF-Coil HF-Coil 040-000586-00000

E11

PCB Brenner Taster Filter PCB Torch Trigger Filter 040-000545-00000

F11

Baugruppe Sättigungswandler Componentry Saturation Transf. 072-000476-00000

G11

Zündgerät Ignition Unit 040-000546-00001

H11

PCB Verbindungsplatine PCB connection 040-000588-00001

I11

Sekundärdioden (8X) Isodul Diode (8X) 064-000840-00004

J11

Magnetventil Solenoid Valve 094-000472-00001

K11

PCB Schutzbeschaltung PCB Protective Wiring 040-000558-00000

L11

Wandler Converter 074-002894-00000

M11

Kondensator Capacitor 092-000500-00005

9 Accessories, options

9/1

9.1 TRITON 260

9.1.1 Standard TIG torch

Designation / description Article No.

WIG torch 26 GD, 4m, two triggers

094-000538-00000

WIG torch 20 WD, 4m, two triggers

094-000487-00000

9.1.2 TIG Up/Down torch

Designation / description Article No.

WIG torch SRT26 Up-Down GD, 4m

094-007549-00000

WIG torch SRT20 Up-Down WD, 4m

094-007535-00000

9.1.3 Electrode holder /workpiece lead

Designation / description Article No.

Electrode holder 35mm2, 4m

092-000052-00000

Workpiece lead 35mm2, 4m, pole binder

092-000008-00000

9.1.4 Remote control / connection cable

Designation / description Article No.

RTF1 foot-operated remote control current On/Off 5m, 19-pole

094-006680-00000

RT1 H remote control current without cable, with holding magnet

090-008097-00000

RT1 H remote control spot/pulse without cable, with holding magnet

090-008098-00000

RT2 H remote control spot/pulse without cable, with holding magnet

090-008099-00000

Remote control connection cable 5m 19-pole

092-001470-00005

Remote control connection cable 10m 19-pole

092-001470-00010

Remote control connection cable 20m 19-pole

092-001470-00020

9.1.5 Miscellaneous accessories

Designation / description Article No.

16A CEE plug

094-000712-00000

TRW 1 transport vehicle

090-008006-00000

Trolley 30-2 building site transport vehicle

090-008092-00000

Trolley 50-2 workshop transport vehicle

090-008103-00000

Cool 30 U20 air-cooling unit

090-008091-00102

DM2 Messer pressure reducer flowmeter 16l/min

094-001980-00000

ADAP1 thread adapter G1/4 to G1/8

094-001650-00000

KF 23E-10 coolant 9.31 (frostpr. -10°C)

094-000530-00000

KF 23E-10 coolant 200l (frostpr. -10°C)

094-000530-00001

KF 37E-20 coolant 9.31 (frostpr. -20°C)

094-006256-00000

9 Accessories, options

9/2

9.2 TRITON 400/500

9.2.1 Standard TIG torch

Designation / description Article No.

WIG torch 18"SC" WD, 4m, two triggers

094-001172-00000

9.2.2 TIG Up/Down torch

Designation / description Article No.

WIG torch 18"SC" UP-DOWN WD, 4m, two triggers

094-007686-00000

9.2.3 Electrode holder /workpiece lead

9.2.3.1 TRITON 400 Designation / description Article No.

Electrode holder 70mm2, 4m

092-000011-00000

Workpiece lead 70 sq.mm, 4m, pole binder

092-000013-00000

9.2.3.2 TRITON 500 Designation / description Article No.

Electrode holder 95mm2, 4m

092-000010-00000

Workpiece lead 35mm2, 4m, pole binder

092-000171-00000

9.2.4 Remote control / connection cable

Designation / description Article No.

RTF1 foot-operated remote control current On/Off 5m, 19-pole

094-006680-00000

RT1 H remote control current without cable, with holding magnet

090-008097-00000

RT1 H remote control spot/pulse without cable, with holding magnet

090-008098-00000

RT2 H remote control spot/pulse without cable, with holding magnet

090-008099-00000

Remote control connection cable 5m 19-pole

092-001470-00005

Remote control connection cable 10m 19-pole

092-001470-00010

Remote control connection cable 20m 19-pole

092-001470-00020

9.2.5 Miscellaneous accessories

Designation / description Article No.

Hose connection set, needed for connecting the cooling unit to the welding machine

092-001519-00000

Opt. T-piece set for simultaneous connection of TIG and MIG/MAG torches in a parallel circuit

090-008152-00000

32A CEE plug

094-000207-00000

Trolley 70-2 workshop transport vehicle

090-008089-00000

COOL 70U40 air-cooling unit

090-008085-00102

COOL 70U41 air-cooling unit

090-008086-00102

DM2 Messer pressure reducer flowmeter 16l/min

094-001980-00000

ADAP1 thread adapter G1/4 to G1/8

094-001650-00000

KF 23E-10 coolant 9.31 (frostpr. -10°C)

094-000530-00000

KF 23E-10 coolant 200l (frostpr. -10°C)

094-000530-00001

KF 37E-20 coolant 9.31 (frostpr. -20°C)

094-006256-00000

10 Circuit diagram

10/1

10.1 TRITON 260

(Circuit diagrams are also in the machine)

10 Circuit diagram

10/2

10 Circuit diagram

10/3

10.2 TRITON 360/500

(Circuit diagrams are also in the machine)

10 Circuit diagram

10/4

10 Circuit diagram

10/5

EWM TRITON 260 DC, TRITON 400 DC, TRITON 500 DC Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual