099 000016 Ewm01

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
inverter
TIG DC welding machines
from 150A – 300A
portable
inverter
TIG 200 DC powerSinus
power
Cooler
inverter
TIG 150 DC
inverter
TIG 250 DC
inverter
TIG 300 DC
These operating instructions must be read before commissioning!

Failure to do so may be dangerous!
Machines 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 Guideline (73/23/EEC)
?EC EMV Directive (89/336/EEC)
(The CE Mark is only required in EC member states)
In compliance with VDE 0544 (EN 60974-1), the machines can be used in environments with
an increased electrical hazard.
 2000 We reserve the right to make amendments. Art. No.: 099-000016-EWM01 Revised: 28.08.2000
EG - Konformitätserklärung
e n t EU - conformity declaration
u m b e i ! Déclaration de Conformidité de U.E.

Name des Herstellers:
d o k r ä t EWM HIGHTEC WELDING GmbH
Name of manufacturer:
Nom du fabricant:
i n a l G e (nachfolgend EWM genannt)
(In the following called EWM)
Or i g e m (nommé par la suite EWM)
Anschrift des Herstellers:

t j e d Dr.- Günter - Henle - Straße 8
lieg
Address of manufacturer: D - 56271 Mündersbach – Germany
Adresse du fabricant: info@ewm.de
Hiermit erklären wir, daß das nachstehend We herewith declare that the machine described Par la présente, nous déclarons que la conception
bezeichnete Gerät in seiner Konzeption und below meets the standard safety regulations of the et la construction ainsi que le modéle, mis sur le
Bauart sowie in der von uns in Verkehr ge- EU- guidelines mentionned below in its conception marché par nous, de láppareil décrit ci - dessous
brachten Ausführung den grundlegenden and construction, as well as in the design put into correspondent aux directives fondamentales de
Sicherheitsanforderungen der unten genannten circulation by us. In case of unauthorized changes, sécurité de la U.E. mentionnées ci- dessous. En cas
EG- Richtlinien entspricht. Im Falle von
unbefugten Veränderungen, unsachgemäßen
e n t n e !
improper repairs and / or unauthorized
modifications, which have not been expressly
de changements non autorisés, de réparations
inadiquates et / ou de modifications prohibeés, qui
Reparaturen und / oder unerlaubten Umbauten,
u m h i
allowed by EWM, this declaration will lose its
c
nónt pas été autorisés expressément par EWM,
o c
die nicht ausdrücklich von EWM autorisiert sind,
verliert diese Erklärung ihre Gültigkeit.
d m
validity.
a
cette déclaration devient caduque.
i n a l a ch
Gerätebezeichnung:
r i g h e
it
Description of the machine:
O
Déscription de la machine:
w
Gerätetyp:
s e d
o
Type of machine:
Type de machine:
n cl
is e
Artikelnummer EWM:
Article number:
Numéro dárticle
Seriennummer:
Serial number:
Numéro de série:
i n a l
Optionen:
r i g i n e ! keine
Options:
Options:
n t o ch
none
aucune
Zutreffende EG - Richtlinien:
m e m a EG - Niederspannungsrichtlinie (73/23/EWG)
c
Applicable EU - guidelines:
o u u t e EU - low voltage guideline
D tàt o
Directives de la U.E. applicables: Directive de la U.E. pour basses tensions
EG- EMV- Richtlinie (89/336/EWG)
EU- EMC guideline
j o i n U.E.- EMC directive
e s t
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 Content Page
Safety instructions................................................................................................................................Safety/1
For your safety ................................................................................................................................. Safety/1
Transportation and set up ....................................................................................................................... Safety/3
Notes on the use of these operating instructions .................................................................................... Safety/3
General ........................................................................................................................................AI/1
About this machine manufactured in inverter technology............................................................................... AI/1
The advantages of inverter technology: ......................................................................................................... AI/1
1 Technical data ..................................................................................................................................... 1/1

1.1 Area of application ...................................................................................................................... 1/1
2 Operating elements ............................................................................................................................ 2/1
3 Function specification logic control ................................................................................................. 3/1

3.1 Logic control ............................................................................................................................... 3/1
3.2 Function sequence of TIG non-latched operation without UP/DOWN-SLOPE........................... 3/5
3.3 Function sequence of TIG non-latched operation with UP/DOWN-SLOPE................................ 3/6
3.4 Function sequence of TIG latched operation with UP/DOWN-SLOPE....................................... 3/7
3.5 MMA welding .............................................................................................................................. 3/8
3.6 Remote controls........................................................................................................................ 3/10
3.7 Interface for mechanised welding (remote control connection socket) ..................................... 3/12
4 Quick start – the shortest way to welding........................................................................................ 4/1
Inhalt/1
Table of Content Page
5 Commissioning ................................................................................................................................... 5/1

5.1 Setting up the welding machine.................................................................................................. 5/1
5.2 Mains connection........................................................................................................................ 5/1
5.2.1 Switching the control transformer to 415V mains voltage ................................................ 5/1
5.3 Welding machine cooling system................................................................................................ 5/2
5.4 Workpiece lead ........................................................................................................................... 5/2
5.5 Electrode holder (MMA welding)................................................................................................. 5/2
5.6 General information on connection of the TIG welding torch...................................................... 5/2
5.6.1 TIG welding torch connection ........................................................................................... 5/3
5.6.2 TIG potentiometer welding torch connection .................................................................... 5/3
5.7 Shielding gas supply................................................................................................................... 5/3
5.7.1 Establishing the gas connections ..................................................................................... 5/3
5.7.2 Currentless testing and setting the amount of shielding gas ............................................ 5/4
6 Adjustment instructions (pending) ................................................................................................... 5/4
7 Maintenance and care ........................................................................................................................ 7/1
8 Operating problems, causes and remedies ..................................................................................... 8/1

inverte
8.1 Customer checklist r TIG 150 DC ......................................................................................... 8/1
inverter
8.2 Customer checklist TIG 200 DC powerSinus .............................................................................. 8/2
inverter
8.3 Customer checklist TIG 250 and 300 DC............................................................................ 8/3
9. Spare parts list .................................................................................................................................... 9/1
10. Accessories....................................................................................................................................... 10/1
11. HF pulse generator HF-DC1/42 and ZGP1/8.0-4............................................................................. 11/1
12 Instruction Manual for Power Cooler Air Blast

inverter
Cooler Unit for a TIG 200 DC powerSinus........................................................................................... 12/1
12.1 Description of Unit .......................................................................................................... 12/1
12.2 Technical Data................................................................................................................ 12/1
12.3 Operating Elements Front and Rear Views of Power Cooler Module ............................ 12/1
12.4 Commissioning ............................................................................................................... 12/2
12.5 Spare Parts List .............................................................................................................. 12/3
13. Circuit diagrams................................................................................................................................ 13/1
Inhalt/2
Safety instructions
For Your Safety:

Warning: Observe accident prevention regulations.
Ignoring the following safety procedures can be fatal.
• Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves.
• Protect eyes and face with protective visor.
Electric shocks can be fatal

• The machine may only be connected to correctly earthed sockets.
• Only operate with intact connection lead including protective conductor and safety plug.
• An improperly repaired plug or damaged mains cable insulation can cause electric shocks.
• The machine may only be opened by qualified and authorised personnel.
• Before opening, pull out the mains plug. Switching off is not sufficient. Wait for 2 minutes
until capacitors are discharged.
• Always put down welding torch, stick electrode holder in an insulated condition.
Even touching low voltages can cause you to jump and lead to accidents, so:
• Safeguard yourself against falls, e.g. from a platform or scaffolding.
• When welding, operate earth tongs, torch and workpiece properly, not in ways for which they
are not intended. Do not touch live parts with bare skin.
• Only replace electrodes when wearing dry gloves.
• Never use torches or earth cables with damaged insulation.
Smoke and gases can lead to breathing difficulties and poisoning.

• Do not breathe in smoke and gases.
• Ensure that there is sufficient fresh air.
• Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarbon fumes can
be converted into poisonous phosgene by ultraviolet radiation.
Workpiece, flying sparks and droplets are hot

• Keep children and animals well away from the working area. Their behaviour is unpredictable.
• Move containers with inflammable or exposive liquids away from the working area.
There is a danger of fire and explosion.
• Never heat explosive liquids, dusts or gases by welding or cutting. There is also a danger of
explosion if apparently harmless substances in closed containers are able to build up excess
pressure when they are heated.
Take care to avoid fire hazards

• Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying, when
parts are glowing or hot slag is present.
• A constant check must be kept on whether fire hazards have been created in the working area.
• Highly inflammable objects, such as matches and cigarette lighters for example, must not be
carried in trouser pockets.
• You must ensure that fire extinguishing equipment - appropriate to the welding process - is
available close to the welding work area and that easy access is possible.
Safety /1
Safety instructions
Take care to avoid fire hazards

• Containers in which fuels or lubricants have been present must be thoroughly cleaned before
welding begins. It is not sufficient simply for the receptacle to be empty.
• After a workpiece has been welded, it must only be touched or brought into contact with
inflammable material when it has cooled down sufficiently.
• Loose welding connections can completely destroy protective conductor systems of interior
installations and cause fires. Before beginning welding work, ensure that the earth tongs are
properly fixed to the workpiece or welding bench and that there is a direct electrical connection
from the workpiece to the power source.
Noise exceeding 70 dBA can cause permanent hearing damage

• Wear suitable earmuffs or plugs.
• Ensure that other people who spend time in the working area are not inconvenienced by the
noise.
Secure gas cylinder

• Place shielding gas cylinders in the holders provided for them and secure with safety chains.
• Take care when handling cylinders; do not throw or heat, guard against them toppling over.
• When moving by crane, take off the gas cylinder from the welding machine.
Caution: 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.
Warning: Electromagnetic interference must be reduced to such a level that it no longer

constitutes interference.
Possible reduction measures:
• Welding machines should be regularly maintained (see Sect. “Maintenance and care”)
• Welding leads should be as short as possible and run closely together on or near to the
ground.
• Selective shielding of other leads and equipment in the environment can reduce radiation.
Caution: 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 /2
Safety instructions
Transport and set-up

• Machines may only be moved and operated in an upright position.
• Before moving, pull out mains plug and place on the machine.
• Secure high-pressure shielding gas cylinder with safety chain to prevent it from toppling
over.
Environmental conditions:
The welding machine can be operated in a location where there is no risk of explosion at
• an ambient temperature of -10°C (plasma machines 0°C) to +40°C and
• a relative air humidity up to 50% at 40°C.
• where the surrounding air is free of unusual amounts of dust, acids, corrosive gases or
substances etc., insofar as they do not occur during welding.
Examples of unusual operating conditions:
Unusual corrosive smoke, vapour, excessive oil vapour, unusual vibrations or jolts, excessive
quantities of dust such as grinding dust etc., severe weather conditions, unusual conditions near
the coast or on board ship.
• When setting up the machine, ensure that air inlets and outlets are unobstructed.
The machine is tested to Protection Standard IP23, i.e.:
• Protection against penetration of solid foreign bodies ∅ > 12mm,
• Protection against water spray up to an angle of 60° to the vertical.
Notes on the use of these operating instructions

These operating instructions are arranged in Sections.
To help you find your way around more quickly, in the margins you will occasionally see, in addition
to sub-headings, icons referring to particularly important passages of text which are graded as
follows depending on their importance:
(Note): Applies to special technical characteristics which the user must note.
(Warning): Applies to working and operating procedures which must be followed

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

precisely to avoid endangering people and includes the “Warning” symbol.
Instructions and lists detailing step-by-step actions in given situations can be recognised
by bullet points, e.g.:
• Insert plug of welding current lead into socket (Sect. 5, G2) and lock.
Meaning of the diagram descriptions:

e.g. (C1) means: Item C / Figure 1 in the respective Section
e.g. (Sect. 3, C1) means: in Section 3 Item C / Figure 1
Safety /3
General
About this machine manufactured in inverter technology

Congratulations.
You have purchased a modern and efficient welding machine in inverter technology.
In contrast to conventional power sources, it does not operate with 50Hz but with a 25kHz primary
driven transistor current source.
The advantages of inverter technology:

• Less effort in changing to another workplace because the machine dimensions and weight are
substantially reduced.
• Lower power consumption and smaller mains ratings by high efficiency (no losses).
• No need for expensive compensating equipment by a high cos phi and a correspondingly
smaller reactive current draw from the mains.
• Functional safety by robust construction, highly integrated electronic circuitry.
• High operating safety by thermal monitors in the power circuit.
• High control dynamics for the welding process. Therefore excellent welding and ignition results
and absolute reproducibility of all welding parameters.
• Welding result independent of mains voltage fluctuations.
• Easily serviced design by the use of modern, modular technology.
The powerSinus – Series:

The machines with powerSinus series have a built-in electronic switching unit which restricts the
current spikes coming from the mains supply and produces a pure Sinus-form of mains current. As
a result 200Amps welding current can be achieved from a 230V plug fused at 16Amps with
a cos phi of 1.
AL/1
1 Technical data
inverter TIG 150 DC TIG 200 DC TIG 250 DC TIG 300 DC

with S -sign powerSinus
Adjustable: 5A - 150A 5A - 200A 5A - 250A 5A - 300A

Welding current
Welding voltage 10,1V - 26V 10V - 28V 10V - 30V 10V - 32V
Mains voltage 1x230V (15%;-40%) 1x230V (15%;-40%) 3x400V (20%;-25%) 3x400V (20%;-25%)
(tolerances) 1x240V (10%;-40%) 1x240V (10%;-40%) 3x415V (15%;-25%) 3x415V (15%;-25%)
Mains frequency 50/60Hz

Mains fuse 1 x 16A 1 x 16A 3 x 16A 3 x 16A
slow-blow
Welding current
TIG / MMA
25%duty cycle - / 150A - / 200A -/- -/-
35%duty cycle 150A / - 200A / - -/- -/-
40%duty cycle -/- -/- -/- 300A / 300A
60%duty cycle 116A / 97A 150A / 130A 250A / 250A 250A / 250A
100%duty cycle 90A / 75A 120A / 100A 190A / 190A 190A / 190A
Load alternation 10min (60% duty cycle ∧ 6 min welding, 4min break)
Workpiece 35mm2 50mm2
Open circuit voltage 100V 75V 106V 106V
Efficiency 85% 89%
cos phi 0,99 1,0 0,99 0,99
Ambient temperature -10°C bis +40°C
Protection IP 23
classification
Insulation class H
Machine cooling fan
Torch cooling gas
Total weight 23kg 22kg 26kg 26kg
Dimensions (LxBxH) 450x290x400mm 530x260x400mm 480x355x400mm 480x355x400mm
Constructed to VDE 0544 und EN 60974-1
standards
S All welding machines which carry the S marking are constructed in accordance
with VDE 0544 (EN 60974-1) and can be used in working with increased hazard
of electrical shock
1.1 Area of application:

This machines are suitable exclusively for:
• TIG DC welding with HF and Liftarc ignition of all metals except aluminium.
• MMA DC welding.
All welding machines which carry the S marking are constructed in accordance with VDE 0544
(EN 60974-1) and can be used in working with increased hazard of electrical shock
1/1
2 Operating elements
H
H
L
A G
F
K E
K F
J
E
A D
J
G D C
B
B C
I I
inverter inverter
Fig. 1 TIG 150 DC Fig. 2 TIG 200 DC powerSinus
F L
A E
J
G D
B C
I
inverter
Fig. 3 TIG 250 DC and inverter TIG300 DC
Item Symbol Description

A Mains ON/OFF Switch (inverter TIG 200 DC powerSinus at rear side)
B Welding cable connector positive + for work piece cable TIG and MMA welding
+
C Welding cable connector - ( for TIG- and MMA welding)
-
D Gas connection G 1/4" with power connection Minus - with HF
E Torch trigger connection socket (5 pole)

F Control panel (see Chap. Logic control)
G Remote control connection socket (14 pole)
H Hand crib
I Rubber feet
J Air inlet openings
K Air outlet openings (Rear side)
BASISCH
L RUTIL 2
1
3 7
8
9
CELL Rotary dial arcforcing device (only TIG 200/250/300)
0 10
ArcForce
2/1
3
3.1
A1 E1 B1 F1 H1 C1 G1
UP-SLOPE I1 DOWN-SLOPE
Logic control
I2
Fig. 1:
50% 0 25 0 25 50%
Function specification
0% 100% 0% 100%
IS I2 12
3/1
I1 4 16
0sec. 20sec.
GAS
Logic control INTIG03

000
AMPERE T
I1 K1 J1 D1 N1 L1 M1
3 Function specification
A1 Rotary switch
The following operating modes can be preselected:
• Non-latched operation without UP-SLOPE / DOWN-SLOPE
• Non-latched operation with UP-SLOPE / DOWN-SLOPE
• Latched operation with UP-SLOPE / DOWN-SLOPE
• MMA operating mode

UP-SLOPE
B1 UP-SLOPE (current increase)
0 25
The increase in current from the ignition current Is (E1) to the main current value
I1 (F1) can be infinitely adjusted between 0-25 sec with this rotary dial.
Definition of UP-Slope and DOWN-Slope:
Rise and fall times are set as angles, the maximum times of 25 sec are reached
when Is = minimum and I1 maximum are selected. A change e.g. in the welding
current I1 (broken line) results in a shortening of the UP-Slope and DOWN-
Slope times.
3/2
DOWN-SLOPE
C1 DOWN-SLOPE (current fall)
0 25
The fall in the main current I1 (F1) to the end-crater current (minimum current)
can be infinitely adjusted between 0 - 25 sec with this rotary dial.
12
D1 4 16
Gas post-flow time
0sec. 20sec.
GAS Selects the gas post-flow time between 0-20 sec.
Note: The gas pre-flow time can be infinitely adjusted internally from 0.2-5 s.
50%
E1 Ignition current
0%
IS
100%
Setting of the ignition current Is (E1) in per cent of the main current I1 (F1)
(search arc in 0% position)
F1 Main current I1 (welding current)

For both TIG/plasma and stick electrode welding, the welding current I1 can be
infinitely adjusted with this rotary dial.
I1
DC operation 5A - maximum current

50%
G1 Secondary current
0%
I2
100%
The secondary current I2 (G1) is infinitely adjustable as a percentage of the main
current I1 (F1). During the welding process, it is possible to switch from the main
nd
current I1 to the secondary current I2 set at any time using the 2 torch trigger.
H1 Green LED power unit On

Lights when the power unit is switched on.
I1 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.
J1 Pre-selection switch (currentless test)

When this toggle switch is in position T, the current source is in the "currentless
test" functioning mode. In this operating mode the power unit is blocked and the
T
welding data and the UP- and DOWN-Slope times can be preset without the
welding current.
Note: Welding is impossible!
Latched operating mode example:
• ⇒
st
Torch trigger pressed (1 step) Display: Ignition current IS
• ⇒
nd
Release torch trigger (2 step) Display runs up to the main current
I1 in the UP-Slope time set
• Press secondary current button ⇒ Display: Secondary current I2
• ⇒
rd
Torch trigger pressed (3 step) Display runs down to the end-crater
current DOWN-Slope time set
• ⇒
th
Release torch trigger (4 step) Display: Ignition current IS
3/3
K1 0000 Digital ammeter

Displays the welding current at all times.
L1 Red LED collective interference

If the collective interference LED lights, 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.
M1 Red LED (water deficiency)

Indicates a water deficiency in water-cooled welding machines.
N1 Changeover switch for selecting the ignition modes

HF
HF ignition:
In HF welding, the arc is initiated without contact by a high-voltage ignition
pulse.
HF
Liftarc ignition:
In welding with Liftarc ignition, on the other hand, the Tungsten electrode is in
contact with the workpiece. The torch trigger is operated and a minimum current
flows. The torch is now removed from the workpiece, the arc ignites and the
welding current set flows according to the operating mode.
3/4
3.2 Function sequence of TIG non-latched operation without

UP/DOWN-SLOPE
E1
Set the rotary switch to the position (non-latched without slope)
N1
Set the changeover switch to the position (HF ignition on)
1st step:
• Operate the torch trigger.
• 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 welding current I1.
• HF is switched off.
2nd step:
• Release the torch trigger.
• The arc extinguishes.
• The gas post-flow time set begins.
Fig. 2 Function sequence of non-latched operation without Slope
3/5
3.3 Function sequence of TIG non-latched operation with

UP/DOWN-SLOPE
E1 Rotary switch in the position (non-latched with slope)
N1 Changeover switch in the position (HF ignition on)
1st step:
• The welding current flows and immediately assumes the value set for the ignition current Is.
• The welding current increases with the gradient set (UP-SLOPE) to the welding current I1.
2nd step:
• The welding current falls with the current gradient set (DOWN-SLOPE) to the end-crater current
IE (minimum current).
• The welding current reaches the end-crater current IE the arc extinguishes.
I1
Welding current
IE
IS
Gas pre Gas post- t

Up-Slope Down-Slope
flow time flow time
Press torch trigger Release torch trigger

(1st step) (2nd step)
Fig. 3 Non-latched function sequence with Slope
3/6
3.4 Function sequence of TIG latched operation with

UP/DOWN-SLOPE
E1
Rotary switch in the position (latched with slope)
N1 Changeover switch in the position (HF ignition on)
I1
secondary current
Welding current
I2
IS
IE
Gas pre Gas post- t

Up-Slope Down-Slope
flow time flow time
Press 1st torch trigger Release 1st torch trigger Press 1st torch trigger Release 1st torch trigger
(1st step) (2nd step) (3rd step) (4th step)
Fig. 4 Latched function sequence
1st step
• Welding current flows and immediately assumes the ignition current value set (search arc at
minimum setting).
3/7
2nd step
• The welding current increases with the gradient set (UP-SLOPE) to the welding current I1.
With the second torch trigger, it is possible to switch to the secondary current operating
point I2 during welding.
3rd step
• The welding current falls with the gradient set (DOWN-SLOPE) to the end-crater current IE
(minimum current).
4th step
• The arc extinguishes.
It is also possible to terminate the welding procedure immediately without DOWN-SLOPE and
st rd
end-crater current By briefly operating the 1 torch trigger (3 step). The current falls to zero
and the gas post-flow time begins.
Automatic cut-out:
In latched operating mode, if no ignition of the arc occurs after operation and release of the
torch trigger or if the arc is interrupted when the torch is moved away, an automatic cut-out
occurs within 3 sec.
The HF, gas and open circuit voltage (power unit) are switched off.
3.5 MMA welding
E1
Rotary switch in the position (electrode)
F1 Select welding current I1 (5A - maximum current).
I1
If welding is performed alternately by different methods, e.g. TIG or MMA, and if a welding
torch 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.
3/8
This machine has the following features in MMA operation:
• Arcforcing
Shortly before the electrode threatens to stick, the arcforcing device sets an increased current
designed to prevent the electrode from sticking.
The value of the increased current depends on the welding voltage and the setting on the
arcforcing rotary dial (Chap. 2, item L).
"Far left" position:

Low arcforcing ⇒ gentle arc,
little increased current before short-circuit.
Used with stick electrodes enveloped with rutile.
"Centre" position:
Moderate arcforcing ⇒ normal arc,
moderate increased current before short-circuit.
Used with stick electrodes enveloped with basic material.
"Far right" position:
High arcforcing ⇒ severe arc,
high increased current before short-circuit.
Used with cellulose stick electrodes.
• Automatic hotstart device

Brief increase in the welding current during ignition time in the millisecond range.
• Hotstart
The hotstart current is infinitely adjustable from the minimum to the main current I1 and the
hotstart time from 0 - 2 sec with the additional remote control FR 35.
The hotstart device makes it possible to ignite and re-ignite critical stick electrodes without
difficulty.
• 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 welding current setting and if
necessary correct it.
3/9
3.6 Remote controls

Only the remote controls described in these operating instructions may be connected!
Plug the remote control into the remote control socket of the welding machine (Chap. 2,
D2) and lock it only when the machine is switched off.
The remote control is detected automatically when the welding machine is switched on.
See the operating instructions of the remote control for detailed information.
Foot-operated remote control FR 21

Functions:
• Welding current "ON/OFF" (switches on after the pedal has been operated).
• Infinitely adjustable welding current (in %) depending on the main current I1
selected on the welding machine.
Commissioning:
• Plug the remote control into the remote control socket of the welding machine or of
the FRA 40 before switching on the welding machine.
Manual remote control FR 30

Functions:
• Infinitely adjustable welding current (in %) depending on the welding current I1
selected on the welding machine.
Commissioning:
• Plug the remote control into the remote control socket of the welding machine or of
the FRA 40 before switching on the welding machine.
Manual remote control FRA 40

Functions:
• The welding current I1 is adjustable in absolute values from the minimum to the
maximum current
(regardless of the welding current selected on the machine)
• The machine can be switched from remote control FRA 40 (switch position up) to
another remote control (switch position down) with the changeover switch.
Commissioning:
• Plug the remote control into the remote control socket of the welding machine
before switching on the welding machine.
• Adjust the measurement range of the welding current display to the maximum
current of the machine.
(DIP toggle switch in the remote control, setting when supplied: 250A)
Special features:
• LED welding current display.
• 10-turn helical potentiometer for accurate setting of welding current.
• Connection facility for further remote controls.
3/10
Manual remote control FRP 10

Functions:
• Pulse / spot (changeover switch on the remote control).
• Pulse / spot and break times infinitely adjustable (2 rotary dials on the remote
control).
Pulse current corresponds to the welding current I1.
Break current corresponds to the secondary current I2 (set on the welding machine).
Commissioning:
• Switch the operating mode selector switch on the welding machine to latched
operation.
Special features:
• Connection facility for remote control FR 21 or FR 30.
Manual remote control FRP 15

Functions:
• Remote control "ON/OFF" (changeover switch on the remote control).
• Pulses "ON/OFF" (changeover switch on the remote control).
• Pulse and break time infinitely adjustable (2 rotary dials on the remote control).
• Pulse current I1 (on the remote control) is set as a percentage of the
welding current I1 selected (on the welding machine).
Break current corresponds to the secondary current I2 (set on the welding machine).
Commissioning:
• Switch on the remote control.
• Switch the operating mode selector switch on the welding machine to latched
operation.
Special features:
• Connection facility for remote control FR 21.
Manual remote control Hotstart FR 35

Functions:
• Remote control "ON/OFF" (changeover switch on the remote control).
• Hotstart current and hotstart time infinitely adjustable.
• The welding current I1 is adjustable in absolute values from the minimum to the
maximum current, that is to say regardless of the welding current selected on the
machine.
Commissioning:
• Switch on the remote control.
Special features:
• Connection facility for remote control FRA 40.
3/11
3.7 Interface for mechanised welding (remote control connection

socket)
The welding current sources feature a very high standard of safety.
This high safety standard is also retained when peripheral equipment is connected for automated
welding if this peripheral equipment fulfils the same criteria, particularly with regard to its 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. Galvanically isolated
relay contacts (galvanically isolated) and control inputs are available at the remote control
connection socket (Chap. 2, G) of the current source for automated applications.
Interface for mechanised welding (EB3)
14-pole connection socket (Chap. 2, G) on the front of the current source:

• External nominal value of the user
• Torch trigger control signal
• Current relay contact to the user (galvanically isolated), maximum load: 100mA, +-15V
• Connection for cable screen
• Current supply +/- 15V
• Choice of "Internal" / "External" nominal value input
Fig. 5 Interface for mechanised welding EB3
3/12
inverter
4.1 TIG 150-300 DC (follow safety instructions)
Preparations Adjustment Fault elimination
• Select ignition current Is (% of I1).

50%
Plug in the mains cable. No HF ignition:
(Remember fuse!) • Set toggle switch to HF position.
0% 100%
IS
• Insert workpiece lead, lock and attach • Set current raising time to I1.
UP-SLOPE
+ No welding current
conductively to the workpiece. • Workpiece lead in "-" socket.
0 25
• Connect welding torch • Set welding current I1 Excess temperature LED lights:
(max. value for remote control). • Duty cycle exceeded >
allow machine to cool
I1
50%
• Establish the torch control connection • Select secondary current I2 (% of I1) Other faults:
with the Tuchel plug.
nd
with 2 torch trigger. • Fault inside the machine >
0%
I2
100%
notify the service department
• Plug in the remote control connector • Time of current fall to minimum current
DOWN-SLOPE
plug 5A
0 25
• Establish the shielding gas supply, • Set the gas post-flow time.
12
4 16
open pressure reducer.
0sec. 20sec.
GAS
• Switch on machine. • Preset with "no-power test" key button

and check torch trigger.
T
• Select the operating mode. • Welding current flows:

signal light lights, does not light > see
fault elimination.
green
BASISCH
RUTIL 2
3 7
8 CELL
For electrode welding:
1
0
9
10 • Set arcforcing
ArcForce
4/1
5 Commissioning
5.1 Setting up the welding machine

Follow safety instructions on the opening pages entitled “For Your Safety”.
• Set up the machine so that there is enough room to adjust the operating elements.
• Ensure that the machine is set up in a stable position and appropriately secured.
5.2 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!
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" section.
• Insert mains plug of the switched-off machine into the appropriate socket.
5.2.1 Reconnecting the mains voltage 400/415V at the control transformer

The Faston plug (arrow) must be set on the transformer according to the mains voltage.
• For 400V: Plug to pin 3 (works setting),
• For 415V: Plug to pin 5.
400V
415V
0V
1 3 5
7 9
Fig.: Control transformer
Machines delivered to countries with mains

voltages which deviate from the standard are 230V 230VV
marked with the following labels:
a) Indication of the mains voltage (at the end of the 400V 400
400V
00V
V
cable)
b) Mains voltage on delivery 415V 41
415
415V
15V
(rear of the machine above the rating plate) c) 460V
0V 46
460V
Netzanschluß-
spannung
Mains voltage
400V 500V
0V 500V
c) Special voltages, for marking according to rewiring
on site (enclosed with the operating instructions) ___V
V ___V
After rewiring for 415V,
(Art. No. label, see Chap. Accessories)
• label c) must be taped over label b) and
• label a) must be removed from the end of the
cable.
5/1
5 Commissioning
5.3 Welding machine cooling system

Observe the following to attain the optimum duty cycle of the power components:
• Ensure that the working area is adequately ventilated,
• Do not obstruct the machine’s air inlets and outlets,
• Metal parts, dust or other foreign bodies must not get into the machine.
5.4 Workpiece lead

Remove paint, rust and dirt from clamping and welding areas with a wire brush! Attach the
workpiece clamp in the immediate vicinity of the welding position! Structural parts, pipes,
rails etc. may not be used as return leads for the welding current if they are not the
workpiece themselves!
A perfect current connection must be ensured where welding benches and appliances are
concerned.
• Insert cable plug of the workpiece lead into the welding current socket (Chap.2, B) and lock by
turning to the right.
MMA welding:
The polarity depends on the instructions of the electrode manufacturer on the electrode
packaging.
5.5 Electrode holder connection (MMA welding)

• Insert cable plug of the stick electrode holder into the welding current socket "+" (Chap. 2, B) or
"-" (Chap. 2, C") and lock by turning to the right.
The polarity depends on the instructions of the electrode manufacturer on the packaging.
5.6 General information on connection of the welding torch

We can only guarantee the perfect functioning of our machines when they are used with
our range of welding torches.
TIG welding torches with a shielded torch trigger control line should not be connected!
1. The welding machines are supplied as standard with torch trigger pin assignment B1 and gas
connection G1/4" (only decentralised).
Fig. 3 Torch trigger variations

Fig. 2: Connection socket connection B1
Torch trigger "BT" on PIN 1 / 2
Secondary current "I1 / I2" on PIN 1 / 3
5/2
5 Commissioning
5.6.1 TIG welding torch

Prepare welding torch according to the welding task in hand (see operating instructions of
the torch).
• Plug the torch trigger plug into the socket (Chap. 2, E) and tighten.
• 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 (only for water-cooled torches).
Decentralised:
• Plug the welding current cable (if it exists) into the socket (Chap. 2, C) and lock by turning to the right.
• Screw the gas connection tightly to the connecting nipple G¼ (Chap. 2, D)
(welding current potential “-”).
Central:
• Plug the central connecting plug into the central connection socket and tighten with the box nut .
5.6.2 TIG potentiometer welding torch

The welding machine must be equipped with the "potentiometer torch connection facility"
option to be able to operate a TIG potentiometer welding torch
(if necessary fit "ASM potentiometer" option, see Accessories Chap.).
Prepare welding torch according to the welding task in hand (see operating instructions of
the torch).
• Plug the torch trigger plug into the socket (Chap.2, E) and tighten.
• Plug the control cable plug into the socket (Chap.2, G) and tighten.
• Engage the rapid-action closure nipple of the torch in the rapid-action closure coupling for
the coolant supply (blue) and return (red) lines (only for water-cooled torches).
Decentralised:
• Plug the welding current cable (if it exists) into the socket (Chap. 2, C) and lock by turning
to the right.
• Screw the gas connection tightly to the connecting nipple G¼ (Chap. 2, D)
(welding current potential “-”).
Central:
• Plug the central connecting plug into the central connection socket and tighten with the box nut.
5.7 Shielding gas supply

5.7.1 Establishing the gas connections
Place the shielding gas cylinder in the cylinder holder and secure it against accidents with
the securing chain!
No impurities must be allowed to enter the shielding gas supply, as these would otherwise
cause blockages. Before connecting the pressure reducer to the gas cylinder, open the
cylinder valve briefly to blow out any dirt present.
All shielding gas connections must be gastight!
• Mount the pressure reducer on the gas cylinder valve.
• Screw the gas hose gastight to the pressure reducer and connecting nipple G ¼" on the rear of
the welding machine.
5/3
5 Commissioning
5.7.2 Currentless testing and setting the amount of shielding gas

Consequences of incorrect shielding gas settings:
Insufficient shielding gas: inadequate gas protection, the indrawn air leads to pores in
the weld seam.
Excessive shielding gas: turbulence may occur, as a result of which air
can penetrate and lead to pores in the weld seam.
• Switch on the machine at the main switch (Chap.2, A).
• Select latched operation mode with the program selector switch (Chap. 3, A1).
• Switch on the changeover switch (currentless test) (Chap. 3, J1) (position T)
• Press and release the torch trigger.
• Slowly open the gas cylinder valve.
• Allow the currentless test to proceed, and if necessary correct the welding current, UP-Slope
DOWN-Slope, secondary current etc.
• Set the required amount of shielding gas on the pressure reducer, about 4 – 15 l/min depending
on the current strength and the material.
• Switch off the pre-selection switch (currentless test) (position 0)
The machine is now ready for welding!
6 Adjusting instructions
ng
rki
wo
in
5/4
7 Maintenance and care
DUnder normal
Die i operating conditions these welding machines are largely maintenance-free and
m Ka of care. However, a number of points should be observed to guarantee fault-free
require garuminimum
pite
ndleg l "W
operationDie of relyour d üb amachine.
enwelding rtu Among these are regular cleaning and checking, as described
E evan erarb ng und P
r g än
below, depending t enH
on e i t
the level eoft contamination flege in the environment and the usage time of the
Sollt zungsblä inweise, und sind " aufgefü
en d
welding machine. t t e rn " R ichtl a u sd hrten
ange ie H
forde Dokume Allgemei inien und iesem Gr inweise
Auß rt we and n t ne the N und may, only
Cleaning, erac testing rd e
repairing
n icht v of H i welding
nwei o r machines
men nicht Richtlbe inien
carried out by
competent hpersonnel. tlass en! In the event orlieof se zto
failure comply finde with mehone
any undfollowing tests
ung g en, k u 3 Jah n S i r gültig the
of Norm
the machine must notkabe nnoperated again öuntil
nnenthe re Ghasiebeen
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n ! en w
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7.1 Cleaning ein! sierte 9-000GA
n Fa R
chhä -EWMx
GB To do this, Thecarefully disconnect the machine from the mains. PULL OUT THE MAINS PLUG!
instru
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(Switching p
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Wait for 2 eminutes until
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The individual ccomponents ume e 3 yshould elin beeshandled re noasen in the
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n t s are m ea r warra a n d sta longer v "Mainten
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7.2 F Repetition
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t r o uver ne sonof s et n
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Test sequence: p rése e s pro W M C o
nter cure xx n signe
un d r aup . s
Quarterly test: 1. Visual check of correct acondition
nger rès d
de m e v
I Le is 2. Measurement of protective conductor ort !resistance otre
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Annualco test:
mp ni, di 1. Visual check of correct condition
r
Le is letament ettive e n 2. Measurement of protective conductor resistance
t e
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pres
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Se i ui 3 a een ucleaning
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r i l otivo capitolo „
ti non a ia 4. e vanti noofn open circuit M voltage
L'ino fosse nz5. ”,Function
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7.2.1 Visual check of correct truzi ono
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The machine must be inspected for externally uò c
ompvisible faults (without richie opening thellemachine). gato During
st l “Istru
this inspection, attention must be paid, for example, o r tareto the followingi a riven
points: zioni
peric ditor
• External faults in mains plug and mains cable, e.g. insulation olo d faults, scorch
i vita
e u
or a torizz marks.
pressure
a
• Defects in anti-kink protection and the strain relief of the connection! lead, mains switch.to!
• 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.
7/1
7 Maintenance and care
7.2.2 Measurement of protective conductor resistance

Measure between safety contact of the mains plug and metal parts which can be touched, e.g.
casing screws. During measuring, the entire length of the machine’s connection lead, especially
near the connection points, must be moved.
The resistance must be < 0.1Ω. The measurement must be performed using at least 200 mA.
7.2.3 Measurement of insulation resistance

The machine must be disconnected from the mains. Open the welding machine and clean carefully
as described in Chap. 7.1. Switch on mains switch.
• Insulation resistance mains current circuit - casing: Measure from a connection of the mains
plug to the casing. 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: Measure from a
connection of the mains plug to a welding current socket. The resistance must be > 5.0 MΩ.
7.2.4 Measurement of open circuit voltage (according to EN 60974-1 /

VDE 0544 T1)
1k0 Diode similar 1N 4007
+ Connect the measuring circuit to the

welding current sockets as shown in Fig. 1.
0k2 The voltmeter must indicate the mean
value. Adjust the potentiometer from 0kΩ to
Input
10nF 6u8F V 5kΩ during the measurement.
0...5k
The measured voltage must not deviate
-
Meqsurement circuit for peak values
from that specified on the rating plate (U0)
by more than 10%.
7.2.5 Function test of the welding machine

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

Repair and maintenance work may only be performed by specialist staff. In all service matters,
always consult your dealer. Return deliveries of defective equipment subject to warranty may only
be made through your dealer.
When replacing parts, use only original spare parts.
When ordering spare parts, the machine type, serial number and item number of the machine, as
well as the type description and item number of the spare part must be quoted.
If repair or maintenance work is carried out on this machine by personnel who are not trained and
authorised to undertake such work, the right to claim under the warranty lapses.
7/2
8 Operating problems, causes and remedies
All machines are subjected to strict manufacturing and final inspection procedures. If, despite this,
something fails to work at any time, please check machine using the following process chart. If
none of the fault elimination procedures described leads to the correct functioning of the machine,
please inform your authorised dealer.
8.1 Customer checklist

8.1.1 Customer checklist (inverter TIG 150 DC)
Switch on the machine

(at the mains switch (Kap. 2, A)
Yes
• Mains supply broken
No • Mains plug not inserted
Machine functioning
• Mains fuse faulty
• Mains power switch faulty
Yes
Press torch trigger
Yes
• Torch connection incorrect (check torch
lead according to circuit diagram)
Green LED lights (Kap. 3, H1)
No • Torch control cable not inserted
power unit / "on"
• Torch or torch trigger faulty
Yes
No • No shielding gas connected
Shielding gas is expelled
• Pressure reducer turned off
Yes
No • Test switch (Kap. 3, J1) in „test“ position

Open circuit voltage (Option)
• yellow LED (Kap. 3, I1) excess temperature
lights (allow machine to cool down)
Yes
HF is applied No • HF toggle switch on Lift-Arc ignition
Yes
No • Welding torch faulty
Welding current • Workpiece lead connected
• Workpiece lead in wrong socket
Yes
• Leaky shielding gas supply
No • Welding torch damaged
Good welding properties
• Tungsten electrode contaminated
• insufficient or excessive shielding gas
Yes
No • Remote control plug not inserted in the
Remote control functions machine
• Remote control or cable defective
8/1
8.1.2 Customer checklist (inverter TIG 200 DC powerSinus)

Yes
Machine functioning
• Mains plug wrongly connected
Yes
Press torch trigger
Yes
power unit / "on"
Yes
Yes

Yes
Yes
Yes
Yes
8/2
8.1.3 Customer checklist (inverter TIG 250 und 300 DC)

Yes
Machine functioning
• Mains plug wrongly connected
Yes
Press torch trigger
Yes
power unit / "on"
Yes
Yes

Yes
Yes
Yes
Yes
8/3
9 Ersatzteilliste / Spare parts list
Abb. 11 Vorderseite inverter TIG 150 DC und inverter TIG 200 DC powerSinus
Fig. 11 Front view inverter TIG 150 DC and inverter TIG 200 DC powerSinus
Abb. 12 Vorderseite inverter TIG 250 DC und inverter TIG 300 DC

Fig. 12 Front view inverter TIG 250 DC and inverter TIG 300 DC
9/1
inverter inverter inverter

Pos. Bezeichnung: Type TIG150DC TIG200DC TIG250DC
powerSinus inverter
TIG300DC
1 Drehknopfdeckel ∅ 31mm 074-000234-00001
Knob cover
2 Drehknopf Pfeilscheibe ∅ 31mm 074-000234-00002
Arrow indicator
3 Drehknopf ∅ 31mm 074-000234-00000
Knob
4 Bedienungsseite mit INTIG 03 - 092-000315-00000 -
Operating side with INTIG 03
Leiterplatte WIG – Steuerung INTIG03/4 - 040-000325-00003 -
PCB TIG control
IC PAL 16L8 D1INTIG03 - 044-001706-00001 -
IC PAL
5 Gehäuseabdeckung 094-000289-00006 094-000857-00009 094-003383-00009
Casing panel
6 Halterung für Griffstange 074-000237-00000
Hand grip mount
7 Griffstange 074-000237-00001 074-000237-00010 074-000237-00002
Hand grip
8 Anschlußbuchse 14 polig EB1 040-000354-00000
Connection socket 14-pole EB3 040-000408-00000
Entstörplatine LC4/1 040-000486-00000
PCB interf. suppression LC3/1 040-000482-00000
9 Anschlußbuchse 5polig 074-000233-00000
Connection socket
10 Anschlußnippel G 1/4" 094-000047-00001
Connection nipple
11 Schweißstrombuchsen 074-000232-00000
Welding current socket
12 Gummifüsse 074-000223-00000
Rubber foot
13 Drehknopf ∅ 23mm 074-000315-00000
Knob
14 Drehknopfdeckel ∅ 23mm 074-000315-00001
Knob cover
15 Drehknopf Pfeilscheibe ∅ 23mm 074-000315-00002
Arrow indicator
16 LED-Anzeige DVM1/1-1 - 040-000385-00000 -
LED-display
17 Kippschalter - 094-001898-00000 -
Toggle switch
18 Schalter 044-001939-00000
Toggle switch
19 Hauptschalter 074-000231-00000 - 074-000279-00001
Main switch
Schaltergriff - - 094-001814-00000
Switch knob
20 PCB WIG-Steuerung AC ACTIG03/2 - 040-000379-00002 -
PCB TIG control AC
Seitenwand - 094-001545-00005 -
Side panel
21 Befestigungswinkel für 094-000112-00000
Tragegurt
Angle bracket, carrying strap
9/2
Abb. 13 Rückseite inverter TIG 150 DC und inverter

TIG 200 DC powerSinu
Fig. 13 Rear view inverter TIG 150 DC and inverter
TIG 200 DC powerSinus
inverter inverter
Abb. 14 Rückseite TIG 250 DC und TIG 300 DC
inverter inverter
Fig. 14 Rear view TIG 250 DC and TIG 300 DC
9/3

powerSinus inverter
TIG300DC
1 Magnetventil 1/4" 074-000227-00000

Solenoid valve
2 Hauptschalter - 074-000231-00000 -
Main switch
3 Netzkabel 074-000236-00001 074-000236-00001 094-000002-00000

Mains cable
4 Schalter 044-001939-00000 - 044-001939-00000

Toggle switch
5 Sicherung träge 094-000202-00000 - 094-000202-00000

Fuse slow-blowing
9/4
Abb. 15 Linke Seite inverter TIG 150 DC

Fig. 15 Left hand side inverter TIG 150 DC
Abb. 16 Linke Seite inverter TIG 200 DC powerSinus

Fig. 16 Left hand side inverter TIG 200 DC powerSinus
Abb. 17 Linke Seite inverter TIG 250 DC und inverter TIG 300 DC
Fig. 17 Left hand side inverter TIG 250 DC and inverter TIG 300 DC
9/5

powerSinus inverter
TIG300DC
1 PCB Schutzbeschaltung DSB5/1 - 040-000448-00000 -

PCB protactive wiring
2 Sekundär SKD6xD370-04F - 072-000330-00000 -
Dioden Kühler 6xD70-04F
3 Zündgerät HF-DC1/42 - 040-000309-00000 -

Ignition unit
4 Inverterbausatz WIG DC26V/150A 220V-S 070-000019-00000
Inverter kit WIG DC28V/200A 230/240V-S 070-000040-00000
WIG DC30V/250A 3x380V-S 070-000005-00000
WIG DC32V/300A 3x400V-L 070-000036-00001
5 Shunt 150A/60mV 074-000359-00000 074-000359-00000 074-000034-00000
Shunt
6 Kabeldurchführung 074-000283-00000 074-000283-00000 074-000243-00000
Cable bushing
7 Lüfter - 074-000015-00000 -
Fan
8 Versorgungstrafo EI 84a/59VA/230-43-20V 074-000298-00000
Supply transformer EI66a/21VA/230V-110-42V 074-000496-00004
EI66a/24VA/415-400-42-0V 094-000588-00001
9 PCB WIG-Steuerung INTIG03/4 040-000325-00003 - 040-000325-00003
PCB TIG control
IC PAL 16L8 D1INTIG03 044-001706-00001 - 044-001706-00001
IC PAL
11 Primärschalter INV 25/500 080-000235-00000
Primary switch DI 70-04GF15 080-000179-00004
D 70-04GF15 080-000178-00004
INV40/1000-1.6M 080-000270-00000
INV45/1000-2.6M 080-000261-00000
12 Primärschalter INV40/1000-1.6P - - 080-000271-00000
Primary switch INV45/1000-2.6P 080-000262-00000
13 Durchflußwandler DC 3.9/220V-02 072-000135-00000 -
DW 7,5/3x380V-01 072-000032-00000
14 PCB Treiberelektronik TRI 1/1 - - 040-000294-00000
PCB driver electronic
15 Varistormodul SB460/6 - - 072-000292-00000
Varistor module
16 PCB Sperrwandler - - 040-000289-00000
PCB blocking converter
17 Netzgleichrichter B2 35/12 080-000238-00012 -
Mains rectifier B6 105/16 080-000205-00016
18 Thyristor-Modul MT 32-10 080-00253-00010 -
Thyristor module MTD55-14A 064-000083-00014
9/6
Abb. 18 Rechte Seite inverter TIG 150 DC

Fig. 18 Right hand side inverter TIG 150 DC
Abb. 19 Rechte Seite inverter TIG 200 DC powerSinus

Fig. 19 Right hand side inverter TIG 200 DC powerSinus
Abb. 20 Rechte Seite inverter TIG 250 DC und inverter TIG 300 DC
Fig. 20 Right hand side inverter TIG 250 DC and inverter TIG 300 DC
9/7

powerSinus inverter
TIG300DC
1 PCB Sperrwandler SPW3/2 - 040-000474-00000 -
PCB blocking converter
2 PCB Haupt- TRSQW3/200/1 - 040-000451-00000
regelungselektronik TRDC2/250/6 040-000290-00015
PCB main regulator TRDC2/300/2 040-000290-00018
electr.onic
3 Durchflußwandler DC 5.0/220V-02 072-000347-00000 -
4 Netzgleichrichter B2 35/12 080-000233-00012 -

Mains rectifier
5 Magnetventil 094-000472-00001
Solenoid valve
6 PCB Hochsetzsteller PFC1/1PCB - 040-000455-00000 -
PCB power factor
correction
7 HF – Filter HF 1-3 040-000284-00000
HF filter
8 PCB WIG-Steuerung INTIG03/4 040-000325-00003
PCB TIG control
IC PAL 16L8 D1INTIG03 044-001706-00001 044-001706-00001
IC PAL
9 Zündgerät HF-DC1/42 040-000309-00000 - 040-000309-00000
Ignition unit
10 PCB Lüfteransteuerung Relais1 - - 040-000404-00000
PCB fan control
11 Sekundär Gleichrichter- MDDM 95-04 F02 080-000149-00004 -
diode und Freilaufdiode MDDM120-04 F02 080-000257-00004
Sec. diode rectifier recov.
diode
12 Lüfter 074-000015-00000 - 074-000015-00000
Fan
13 PCBSchutzbeschaltung DSB1/1 040-000298-00000 -
PCB protective wiring DSB3/5 040-000446-00000
14 Sekundär SDK 2x MDDM 95-04 F02-01/3 072-000159-00000 -
Dioden Kühler SDK 2x MDDM 120-04 F02-01/2 072-000154-00000
Secundary diode cooler
15 PCB (Liftarc) Lift 1/DC - - 040-000434-00000
PCB (liftarc)
16 Shunt 150A/60mV 074-000359-00000 -
Shunt 250A/60mV 074-000034-00000
9/8
10 Zubehör
10.1 Torches / electrode holders

Description Designation Article No.
2
Electrode holder with 4 m cable 50 mm EH 50 092-000004-00000
2
Electrode holder with 4 m cable 70 mm EH 70 092-000011-00000
2
Workpiece lead with 4 m cable 50 mm and clamp WK50QMM-4M/K 092-000003-00000
"ASM" potentiometer torch connection OW 092-001097-00000
ASM Potibrenner
2
Workpiece lead with 4 m cable 70 mm and clamp WK70QMM-4M/K 092-000013-00000
TIG-Poti-torch, gas, central SRT17 1Poti GZ, 4m 094-003422-00000
TIG-Poti- torch, gas, decentralised SRT17 1Poti GD, 4m 094-003423-00000
TIG-Poti- torch, gas, central SRT26 1Poti GZ, 4m 094-003424-00000
TIG-Poti- torch, gas, decentralised SRT26 1Poti GD, 4m 094-003425-00000
TIG-Poti- torch, water, central SRT18 1Poti WZ, 4m 094-003426-00000
TIG-Poti- torch, water, decentralised SRT18 1Poti WD, 4m 094-003427-00000
TIG-Poti- torch, water, central SRT20 1Poti WZ, 4m 094-003428-00000
TIG-Poti- torch, water, decentralised SRT20 1Poti WD, 4m 094-003429-00000
For operation with a TIG poti torch the machine has to be equipped with the option
„connection poti torch possible!“
10.2 Remote controls

Manual remote control spot / pulse with 5 m cable FRP 10 090-008002-00000
Manual remote control current / spot / pulse with FRP 15 090-008045-00000
5 m cable
Manual remote control current with 5 m cable FR 30 090-008005-00000
Manual remote control hotstart with 5 m cable FR 35 090-008044-00000
Manual remote control current with digital amm. FRA 40 090-008032-00000
and 0.3 m cable
Foot-operated remote control current with 5 m cable FR 21 094-000051-00000
Extension cable for remote controls with 3 m cable FRV 3 092-000005-00003
10.3 Miscellaneous accessories

Adhesive film label "400V cable" 094-007249-00000
10/1
11 HF pulse generator HF-DC1/42 and ZGP1/8.0-42
Before all work on the pulse generator, switch off the supply voltage and remove the mains
plug! Repairs by electricians only.
11.1 Technical data

Type HF pulse generator HF-DC 1/42 ZGP 1/8.0-42
Nominal input voltage 42VAC 42VAC
Permissible deviation +/- 10% +/- 10%
Rated frequency 50/60Hz 50/60Hz
Rated input power 5VA 12VA
Rated output peak voltage 8kV 8kV
11.2 Application
Pulse generators for installation in current sources or electrical cabinets serve for non-contact
ignition of the arc for welding with direct current.
Optimum ignition characteristics are only ensured with torch tube package lengths up to
max. 8m.
11.3 Maintenance
The internal pulse generator, designed to ignite and stabilise the arc, delivers high-voltage ignition
pulses whose power is to be applied without losses to the electrode.
However, any dirt, dust, moisture, oil etc. reduces the insulating properties of the required air and
creep gaps. It must therefore be ensured that the equipment is looked after and kept clean by
regular maintenance.
This also applies particularly to the torches (often heavy contamination in the area of the grip).
Contamination here often becomes noticeable when the HF leads to "electrification". In principle, the
applied HF is safe (high frequency characteristics, so-called skin effect), but can lead to startled
reactions. When the HF becomes noticeable, it takes routes which reduce the power at the gap
between the electrode and the workpiece. It is therefore essential to ensure that the torches are
clean and looked after!
The pulse generator itself is maintenance-free.
11.4 Safety precautions

Due to the very short ignition pulses (< 1 µsec), the pulse voltage is not dangerous. However,
unexpected "electrification" can cause alarm. Therefore, wear suitable protective clothing for
welding (in the Federal Republic of Germany, to UVV/VBG 15). Use only well-insulated welding
torches and electrode holders. Perform work on welding torches and replace the electrode only
when the current source is switched off.
11/1
12.1 Description of Unit

The power cooler is used for recirculating and cooling welding torch coolant.
The cooling unit is fitted with an Air Blast heat exchanger, therefore the efficiency of the cooling unit
is affected directly by the ambient temperature. The lower the Ambient temperature, the cooler the
air passing through the heat exchanger, therefore the higher the cooling effect. The operating
pressure of the coolant is monitored by a pressure switch, in the case of pressure loss then the
operation of the torch button control signal will be unlimited.
The built in coolant recirculation pump is fitted with a protective current overload.
The supply voltage for this unit is fed internally from the welding power source.
Application Range:
The power cooler, is only suitable for use in conjunction with the following welding machine
inverter TIG 200 DC powerSinus
12.2 Technical Data:

power Cooler
Mains voltage 1x230V
Mains frequency 50/60Hz
Max. torch loading 200A bei 35% ED
Maximum cooling capacity 1800 W
Maximum coolant pressure 3,8 bar
Working temperature range -10°C up to +40°C
Protection classification IP 23
Insulation classification H
Type of cooling Lüfter
Coolant contents 5 Liter
Coolant type Coolant KF23E - 10
Weight 39kg
(incl. inverter TIG 200 DC powerSinus without coolant)
Dimensions (LxBxH) 640 x 280 x 305mm
Dimensions (LxBxH) 640 x 280 x 620mm
incl. inverter TIG 200 DC powerSinus
12.3 Operating elements front and rear views of power Cooler module
Fig 21:
Operating elements front and rear view of power cooler module with inverter TIG 200 DC powerSinus
12/1
A10 Quick release coupling, coolant return from welding torch
B10 Quick release coupling, coolant supply to welding torch
C10 Viewing window (coolant level)

D10 Filler inlet coolant (with screwcap lid and sieve)
E10 Current overload cut-out for coolant pump
12.4 Commissioning
Please read the safety information on pages 3 + 4 before proceeding further
Operating environment
The working life of the cooling unit can be seriously affected, by various amounts, of Dirt, Dust,
Acids, Corrosive gases, or metallic particles being present in the air of the working environment.
Position the machine so that the Air flow into and out of the unit is completely unrestricted.
Coolant
The machine becomes from factory with a coolant-minimum filling KF23E-10 delivered.
With the coolant KF23E-10 is guaranteed antifreezes to –10 °C!
Coolant stood examine and if necassary up to the upper shop-window of the tank (C10) coolants
KF23E-10 (Article No.: if accessory see) refill.
Using a mixture of other coolants, or using a coolant other than one prescribed above will
void the manufacturers guarantee.
The filter must be in the filler rack when filling the unit.
Characteristic of the integrated water pump
Putting:
H [in m] conveyor high
P [in W] submitted pumping power
Q [l/min] conveyor quantity
Q [m /h]
3
conveyor quantity
The power cooler is now ready for use!
12/2
12.5 Spare parts list:
10
7
11 8
9
Fig 23: Fig 24:

left hand side power Kühlmodul right hand side power Kühlmodul
Fig 22:
Front view power Cooler with inverter TIG 200 DC powerSinus
Pos. Description: power

Cooler
1 Side panel (left) 094-001645-00005
2 Rubber feet 074-000223-00000
3 Water connection (blue) 094-000521-00000
4 Water connection (red) 094-000520-00000
5 Housing cover 094-001644-00000
6 Side panel (right) 094-001686-00005
7 Fan 074-000015-00000
8 Overload -
9 Recirculating Pump 094-001755-00000
10 Druckschalter 094-000232-00001
11 Heat exchanger 094-001691-00000
12 Tank 094-001589-00000
KF 23E-10 094-000530-00000
12/3
13 Schaltpläne / Circuit Diagrams
inverter
13.1 TIG 150 DC
(Schaltpläne befinden sich ebenfalls im Gerät)
13/1
inverter
13.2 TIG 200 DC powerSinus
13/2
inverter
13.3 TIG 200 DC powerSinus + power Kühlmodul
13/3
inverter
13.4 TIG 250/300 DC
13/4

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EWM HIGHTEC WELDING GmbH

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

These operating instructions must be read before commissioning!

u m b e i ! Déclaration de Conformidité de U.E.

Or i g e m (nommé par la suite EWM)

Anschrift des Herstellers:

o u u t e EU - low voltage guideline

j o i n U.E.- EMC directive

Michael Szczesny , Geschäftsführer

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

2 Operating elements ............................................................................................................................ 2/1

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

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

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

6 Adjustment instructions (pending) ................................................................................................... 5/4

7 Maintenance and care ........................................................................................................................ 7/1

8 Operating problems, causes and remedies ..................................................................................... 8/1

9. Spare parts list .................................................................................................................................... 9/1

10. Accessories....................................................................................................................................... 10/1

11. HF pulse generator HF-DC1/42 and ZGP1/8.0-4............................................................................. 11/1

12 Instruction Manual for Power Cooler Air Blast

13. Circuit diagrams................................................................................................................................ 13/1

For Your Safety:

Electric shocks can be fatal

Smoke and gases can lead to breathing difficulties and poisoning.

Workpiece, flying sparks and droplets are hot

Take care to avoid fire hazards

Take care to avoid fire hazards

Noise exceeding 70 dBA can cause permanent hearing damage

Secure gas cylinder

Warning: Electromagnetic interference must be reduced to such a level that it no longer

Transport and set-up

Notes on the use of these operating instructions

(Warning): Applies to working and operating procedures which must be followed

(Caution): Applies to working and operating procedures which must be followed

Meaning of the diagram descriptions:

About this machine manufactured in inverter technology

The advantages of inverter technology:

The powerSinus – Series:

inverter TIG 150 DC TIG 200 DC TIG 250 DC TIG 300 DC

Adjustable: 5A - 150A 5A - 200A 5A - 250A 5A - 300A

Mains frequency 50/60Hz

1.1 Area of application:

Item Symbol Description

E Torch trigger connection socket (5 pole)

Logic control INTIG03

• Non-latched operation without UP-SLOPE / DOWN-SLOPE

• Non-latched operation with UP-SLOPE / DOWN-SLOPE

• Latched operation with UP-SLOPE / DOWN-SLOPE

• MMA operating mode

B1 UP-SLOPE (current increase)

Definition of UP-Slope and DOWN-Slope:

C1 DOWN-SLOPE (current fall)

F1 Main current I1 (welding current)

DC operation 5A - maximum current

H1 Green LED power unit On

I1 Yellow LED (excess temperature)

J1 Pre-selection switch (currentless test)

K1 0000 Digital ammeter

L1 Red LED collective interference

M1 Red LED (water deficiency)

N1 Changeover switch for selecting the ignition modes

3.2 Function sequence of TIG non-latched operation without