Related Manuals for EWM alpha Q 551
Summary of Contents for EWM alpha Q 551
- Page 1 Operating instructions Welding machine alpha Q 351 alpha Q 551 099-005130-EW501 Observe additional system documents! 07.03.2013 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
-
Page 2: General Instructions
© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer. -
Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................6 General ............................7 Transport and installation ......................11 2.4.1 Lifting by crane ...................... - Page 4 Interface for automated welding ................... 42 Vent coolant circuit ........................43 8 Technical data............................44 alpha Q 351 ..........................44 alpha Q 551 ..........................45 9 Accessories ............................46 System components ........................46 General accessories ........................46 Options ............................46 Remote control/connecting and extension cable .................
-
Page 5: Safety Instructions
Safety instructions Notes on the use of these operating instructions Safety instructions Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... -
Page 6: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Press Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu) EXIT EXIT (Exit the menu) Time display (example: wait 4s/press) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use... -
Page 7: General
Safety instructions General General DANGER Electric shock! Welding machines use high voltages which can result in potentially fatal electric shocks and burns on contact. Even low voltages can cause you to get a shock and lead to accidents. • Do not touch any live parts in or on the machine! •... - Page 8 Safety instructions General WARNING Explosion risk! Apparently harmless substances in closed containers may generate excessive pressure when heated. • Move containers with inflammable or explosive liquids away from the working area! • Never heat explosive liquids, dusts or gases by welding or cutting! Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning.
- Page 9 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
- Page 10 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data): Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
-
Page 11: Transport And Installation
Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •... -
Page 12: Lifting By Crane
Safety instructions Transport and installation 2.4.1 Lifting by crane DANGER Risk of injury during lifting by crane! When lifting the equipment by crane, serious injuries can be inflicted by falling equipment or add-on units. • Transport on all lifting lugs at the same time (see Fig. -
Page 13: Ambient Conditions
Safety instructions Transport and installation 2.4.2 Ambient conditions CAUTION Installation site! The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work. -
Page 14: Intended Use
Intended use Applications Intended use This machine has been manufactured according to the latest developments in technology and current regulations and standards. It must only be operated in line with the instructions on correct usage. WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. -
Page 15: Use And Operation Solely With The Following Machines
Intended use Use and operation solely with the following machines Use and operation solely with the following machines NOTE A suitable power source (system component) is required in order to operate the wire feed unit! alpha Q 351 D 551 D 351 2DV 551 2DV ... -
Page 16: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-005130-EW501 07.03.2013... - Page 17 Machine description – quick overview Front view Item Symbol Description Lifting lug Ready for operation signal light Signal light on when the machine is switched on and ready for operation Main switch, machine on/off Carrying handle Cooling air inlet Wheels, guide castors Coolant tank Coolant tank cap Automatic cut-out of coolant pump key button...
-
Page 18: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 099-005130-EW501 07.03.2013... - Page 19 Machine description – quick overview Rear view Item Symbol Description 7-pole connection socket (digital) For connecting digital accessory components 7-pole connection socket (digital) Wire feed unit connection PC interface, serial (D-Sub connection socket, 9-pole) 19-pole mechanised welding interface (analogue) (See chapter entitled "Design and function > interfaces".) Connection socket, “+”...
-
Page 20: Design And Function
Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •... -
Page 21: Installation
Design and function Installation CAUTION Damage due to incorrect connection! Accessory components and the power source itself can be damaged by incorrect connection! • Only insert and lock accessory components into the relevant connection socket when the machine is switched off. •... -
Page 22: Notes On The Installation Of Welding Current Leads
Design and function Notes on the installation of welding current leads Notes on the installation of welding current leads NOTE Incorrectly installed welding current leads can cause faults in the arc (flickering). Install welding lead and hose package in parallel and as close together as possible. Keep the welding lead and hose packages of each welding machine separate, with an installation distance of at least 15 cm! Fully unroll welding current leads, torch hose packages and intermediate hose... -
Page 23: Welding Torch Cooling System
Design and function Welding torch cooling system Welding torch cooling system 5.6.1 General CAUTION Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void! • Only use the coolant described in this manual (overview of coolants). •... -
Page 24: Adding Coolant
Design and function Welding torch cooling system 5.6.3 Adding coolant NOTE After the initial filling, wait for at least one minute when the machine is switched on so that the tube package is filled with coolant completely and without bubbles. With frequent changes of torch and during the initial filling process, the cooling unit tank should be topped up as necessary. -
Page 25: Mains Connection
Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations! •... -
Page 26: Intermediate Hose Package Connection
Design and function Intermediate hose package connection Intermediate hose package connection NOTE Note the polarity of the welding current! Some wire electrodes (e.g. self-shielding cored wire) are welded using negative polarity. In this case, the welding current lead should be connected to the "-" welding current socket, and the workpiece lead should be connected to the "+"... -
Page 27: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Shielding gas supply (shielding gas cylinder for welding machine) • Insert the end of the hose package through the strain relief of the hose package and lock by turning to the right. • Insert the plug on the welding current lead into the welding current connection socket "+" and lock. •... - Page 28 Design and function Shielding gas supply (shielding gas cylinder for welding machine) Figure 5-5 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve • Place the shielding gas cylinder into the relevant cylinder bracket. •...
-
Page 29: Mig/Mag Welding
Design and function MIG/MAG welding 5.10 MIG/MAG welding 5.10.1 Connection for workpiece lead NOTE Note the polarity of the welding current! Some wire electrodes (e.g. self-shielding cored wire) are welded using negative polarity. In this case, the welding current lead should be connected to the "-" welding current socket, and the workpiece lead should be connected to the "+"... -
Page 30: Tig Welding
Design and function TIG welding 5.11 TIG welding 5.11.1 Welding torch connection NOTE TIG welding torches to be connected to a Euro torch connector are available in two versions: • TIG combi welding torches are connected to the Euro torch connector of the wire feeder and to the (-) welding current plug of the power source. -
Page 31: 5.11.2 Connection For Workpiece Lead
Design and function TIG welding • Insert the central plug for the welding torch into the central connector and screw together with crown nut. • Insert the welding current plug of the combi welding torch into the (-) welding current connection socket and lock into place by turning to the right (only in case of a separate welding current connection). -
Page 32: Mma Welding
Design and function MMA welding 5.12 MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •... -
Page 33: Interfaces
Design and function Interfaces 5.13 Interfaces CAUTION Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •... -
Page 34: 5.13.2 Rint X12 Robot Interface
Design and function PC Interfaces 5.13.2 RINT X12 robot interface The standard digital interface for mechanised applications (optional, retrofitting on the machine or external fitting by the customer) Functions and signals: • Digital inputs: start/stop, operating modes, JOB and program selection, inching, gas test •... -
Page 35: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER Risk of injury from electric shock! Cleaning machines that are not disconnected from the mains can lead to serious injuries! • Disconnect the machine completely from the mains. • Remove the mains plug! •... -
Page 36: Monthly Maintenance Tasks
Maintenance, care and disposal Maintenance work 6.2.2 Monthly maintenance tasks 6.2.2.1 Visual inspection • Casing damage (front, rear and side walls) • Wheels and their securing elements • Transport elements (strap, lifting lugs, handle) • Check coolant tubes and their connections for impurities 6.2.2.2 Functional test •... -
Page 37: Disposing Of Equipment
Information about giving back used equipment or about collections can be obtained from the respective municipal administration office. • EWM participates in an approved waste disposal and recycling system and is registered in the Used Electrical Equipment Register (EAR) under number WEEE DE 57686922. •... -
Page 38: Rectifying Faults
Rectifying faults Checklist for rectifying faults Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dealer. -
Page 39: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) NOTE A welding machine error is indicated by an error code being displayed (see table) on the display on the machine control. In the event of a machine error, the power unit is shut down. The display of possible error numbers depends on the machine version (interfaces/functions). - Page 40 Rectifying faults Error messages (power source) Legend for categories (error reset) a) The error message will disappear once the error has been rectified. b) The error message can be reset by pressing a key button: Welding machine control Key button RC1 / RC2 Expert CarExpert / Progress (M3.11)
-
Page 41: Resetting Jobs (Welding Tasks) To The Factory Settings
Rectifying faults Resetting JOBs (welding tasks) to the factory settings Resetting JOBs (welding tasks) to the factory settings 7.3.1 Resetting a single JOB NOTE All customised welding parameters that are stored will be replaced by the factory settings. RESET ENTER JOB- JOB- LIST... -
Page 42: Resetting All Jobs
Rectifying faults General operating problems 7.3.2 Resetting all JOBs NOTE JOBs 1–128 and 170–256 will be reset. Custom JOBs 129–169 are maintained. RESET ENTER JOB- JOB- LIST LIST EXIT m /m in Figure 7-2 Display Setting/selection Reset to factory settings The RESET will be done after pressing the button. -
Page 43: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit NOTE To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! Figure 7-3 099-005130-EW501 07.03.2013... -
Page 44: Technical Data
Technical data alpha Q 351 Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! alpha Q 351 MIG/MAG Setting range for welding current 5 A–350 A Setting range for welding voltage 14.3 V–31.5 V 20.2 V–34.0 V 10.2 V–24.0 V Duty cycle at 40 °C... -
Page 45: Alpha Q 551
Technical data alpha Q 551 alpha Q 551 MIG/MAG Setting range for welding current 5 A– 550 A Setting range for welding voltage 14.3 V–41.5 V 20.2 V–42.0 V 10.2 V–32.0 V Duty cycle at 25 °C 550 A (60%) -
Page 46: Accessories
Accessories System components Accessories NOTE Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. System components Type Designation Item no. alpha Q drive 4L MIG/MAG wire feed unit 090-005125-00502 alpha Q drive 4L RE Wire feeder, water, Euro torch connector 090-005156-00502 alpha Q drive 200C... -
Page 47: Remote Control/Connecting And Extension Cable
Accessories Remote control/connecting and extension cable Remote control/connecting and extension cable 9.4.1 7-pole connection Type Designation Item no. R40 7POL Remote control, 10 programs 090-008088-00000 R50 7POL Remote control, all welding machine functions can 090-008776-00000 be set directly at the workplace FRV 7POL 0.5 m Extension/connecting cable 092-000201-00004... -
Page 48: Overview Of Ewm Branches
Appendix A Overview of EWM branches Appendix A 10.1 Overview of EWM branches 099-005130-EW501 07.03.2013...
Need help?
Do you have a question about the alpha Q 551 and is the answer not in the manual?
Questions and answers