+49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment.
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................5 Notes on the use of these operating instructions ................5 2.1.1 Explanation of icons ....................... 6 Part of the complete documentation ....................7 3 Machine control –...
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Display machine control software version ..................74 6 Appendix A ............................75 Parameter overview – setting information ..................75 6.1.1 TIG welding ........................75 6.1.2 MMA welding ........................ 76 7 Appendix B ............................77 Overview of EWM branches......................77 099-00T400-EW501 21.10.2016...
For your safety Notes on the use of these operating instructions For your safety 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. •...
For your safety Notes on the use of these operating instructions 2.1.1 Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release/tap/tip user must observe. Switch off machine Release Switch on machine Press and keep pressed Switch Wrong Turn...
For your safety Part of the complete documentation Part of the complete documentation These operating instructions are part of the complete documentation and valid only in combination with all other parts of these instructions! Read and observe the operating instructions for all system components, especially the safety instructions! The illustration shows a general example of a welding system.
Machine control – Operating elements Overview of control sections Machine control – Operating elements Overview of control sections For description purposes, the machine control has been divided into three sections (A, B, C) to ensure maximum clarity. The setting range for the parameter values are summarised in the parameter overview section >...
Machine control – Operating elements Overview of control sections 3.1.1 Control section A Figure 3-2 Item Symbol Description Welding data display (3-digit) Displays the welding parameters and the corresponding values > see 3.2 chapter Push-button gas test / rinse hose package > see 4.1.1 chapter Operating mode/power-saving mode push-button --------- Latched >...
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Machine control – Operating elements Overview of control sections Item Symbol Description Welding procedure push-button --------- TIG welding ---- MMA welding (signal light turns green) ---- Arcforce setting (signal light turns red) Display switching push-button kW ------- Welding power display V --------- Welding voltage display JOB ----- Display and setting of the JOB number with the control button Welding data display (3-digit)
Machine control – Operating elements Overview of control sections 3.1.2 Control section B Figure 3-3 Item Symbol Description Parameter selection push-button, left The welding sequence parameters are selected one after another in an anti-clockwise direction. Control button Central control button to be pressed or turned > see 3.2 chapter. Parameter selection push-button, right The welding sequence parameters are selected one after another in a clockwise direction.
Machine control – Operating elements Overview of control sections Item Symbol Description Gas pre-flow time signal light activArc TIG welding process • Switch activArc <> • Correct the activArc characteristic > see 4.1.20 chapter Signal light, two colour Green: AC frequency (TIG)/pulse frequency (MMA) Red: Pulse frequency (TIG, kHz pulsing) 3.1.3 Control section C...
Machine control – Operating elements Machine display Machine display The following welding parameters can be displayed before (nominal values), during (actual values) or after welding (hold values): "left display" Parameter Before welding During welding After welding (nominal values) (actual values) (hold values) ...
Machine control – Operating elements Operating the machine control Operating the machine control 3.3.1 Main screen The machine control switches to the main screen after it has been turned on or a setting has been completed. This means that the previously selected settings (indicated by signal lights where applicable) and the nominal value for the current (A) are displayed in the left-hand welding data display.
Welding procedure TIG welding Welding procedure TIG welding 4.1.1 Setting the shielding gas volume (gas test)/rinse hose package • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. •...
Welding procedure TIG welding 4.1.2 Welding task selection The setting of the tungsten electrode diameter has a direct influence on the machine functionality, TIG ignition behaviour and minimum current limits. The ignition energy is controlled by the set electrode diameter. Smaller electrode diameters requires less ignition current and less ignition current time than greater electrode diameters.
Welding procedure TIG welding 4.1.2.1 Recurring welding tasks (JOB 1–7) The user has 7 more memory locations at their disposal to save recurring or different welding tasks on a permanent basis. To do so, simply select the required memory location (JOB 1–7) and the welding task is set as described previously.
Welding procedure TIG welding 4.1.3 Tungsten balling function The tungsten balling function provides optimum tungsten balling, ensuring that the best ignition and welding results are achieved during AC welding. Optimum tungsten balling requires a sharpened electrode (about 15–25°) and the set electrode diameter on the machine control.
Welding procedure TIG welding 4.1.4 AC balance (optimise cleaning effect and penetration characteristics) To weld aluminium and aluminium alloys, AC welding is used in combination with a continuous change in polarity of the tungsten electrode. The process encompasses two phases (half-waves): a positive and a negative one.
Welding procedure TIG welding 4.1.5 AC amplitude balance As with AC balance, durations (balance) for positive phase and negative phase are set for AC amplitude balance. The balance changes in terms of the current amplitude. Figure 4-5 Increasing the current amplitude in the positive half-wave facilitates the cleaning effect and the cracking of the oxide layer.
Welding procedure TIG welding 4.1.6 Arc ignition 4.1.6.1 HF ignition Figure 4-6 The arc is started without contact from high-voltage ignition pulses. a) Position the welding torch in welding position over the workpiece (distance between the electrode tip and workpiece should be approx. 2-3mm). b) Press the torch trigger (high voltage ignition pulses ignite the arc).
Welding procedure TIG welding 4.1.7 Function sequences/operating modes 4.1.7.1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 Current Time Gas pre-flow Ignition current Up-slope time Spot time Main current (minimum to maximum current) Secondary current AMP% Pulse time Pulse pause time...
Welding procedure TIG welding 4.1.7.2 Non-latched mode Figure 4-8 1st cycle: • Press torch trigger 1 and hold down. • Gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece. The arc ignites. • The welding current flows and immediately assumes the value of the ignition current •...
Welding procedure TIG welding 4.1.7.3 Latched mode Figure 4-9 1st cycle • Press torch trigger 1; gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece. The arc ignites. • Welding current flows and immediately assumes the set ignition current (search arc at minimum setting).
Welding procedure TIG welding 4.1.7.4 spotArc This process is suitable for tack welding or joint welding of metal sheets made from steel and CrNi alloys up to a thickness of approximately 2.5 mm. Metal sheets of different thicknesses can also be welded on top of one another.
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Welding procedure TIG welding Figure 4-11 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however > see 4.1.6.2 chapter. Sequence: • Press torch trigger and hold down. • The gas pre-flow time elapses. •...
Welding procedure TIG welding 4.1.7.5 spotmatic In contrast to spotArc operating mode, the arc is not ignited by pressing the torch trigger as is usual, but by briefly touching the tungsten electrode against the workpiece. The torch trigger is used for welding process activation.
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Welding procedure TIG welding Figure 4-13 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, however > see 4.1.6.2 chapter. Selecting the process activation type for the welding process > see 4.7 chapter. Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 sec) only.
Welding procedure TIG welding 4.1.7.6 Non-latched operation, version C Figure 4-14 1st cycle • Press torch trigger 1 , the gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece. The arc ignites. • Welding current flows and immediately assumes the set ignition current (search arc at minimum setting).
4.1.8 TIG activArc welding The EWM activArc process, thanks to the highly dynamic controller system, ensures that the power supplied is kept virtually constant in the event of changes in the distance between the welding torch and the weld pool, e.g. during manual welding. Voltage losses as a result of a shortening of the distance between the torch and molten pool are compensated by a current rise (ampere per volt - A/V), and vice versa.
Welding procedure TIG welding 4.1.10 Pulse welding The following pulse types can be selected: • Automated pulsing (TIG DC) • Thermal pulsing (TIG AC or TIG DC) • Average value pulsing (TIG AC or TIG DC) • Metallurgical pulsing (TIG DC) •...
Welding procedure TIG welding 4.1.10.2 Thermal pulsing The operation sequences basically match the standard welding sequences, but there is an additional switching back and forth between the main current AMP (pulse current) and the secondary current AMP% (pulse pause current) at the set times. Pulse and pause times and the pulse edges ( ) are entered in seconds on the control.
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Welding procedure TIG welding Selection Figure 4-19 Pulse time setting EXIT Figure 4-20 Pulse pause setting EXIT Figure 4-21 Pulse edge setting pulse edges can be set in the Expert menu (TIG) > see 4.1.20 chapter. 099-00T400-EW501 21.10.2016...
Welding procedure TIG welding 4.1.10.3 Average value pulsing Average value pulsing is a variant of pulsing, with the particularity that the power source will always maintain the preset average value. This makes this method especially suitable for welding according to welding procedure specifications.
Welding procedure TIG welding 4.1.10.4 Metallurgical pulsing (kHz pulsing) Metallurgical pulsing (kHz pulsing) uses the plasma force (arc force) occurring at high currents which allows you to achieve a constricted arc with concentrated heat input. Unlike thermal pulsing, no times are set;...
Welding procedure TIG welding 4.1.10.5 AC special Is e.g. used to join metal sheets of different thickness. Figure 4-28 Figure 4-29 pulse edges can be set in the Expert menu (TIG) > see 4.1.20 chapter. 099-00T400-EW501 21.10.2016...
Welding procedure TIG welding 4.1.11 Welding torch (operating variants) Different torch versions can be used with this machine. Functions on the operating elements, such as torch triggers (TT), rockers or potentiometers, can be modified individually via torch modes. Explanation of symbols for operating elements: Symbol Description Press torch trigger...
Welding procedure TIG welding 4.1.12.1 Standard TIG torch (5-pole) Standard torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT1 = Torch trigger 1 (welding current on/off; secondary current via tapping function) Functions mode Operating elements Welding current On/Off (factory-set) Secondary current (Latched mode) Standard torch with two torch triggers:...
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Welding procedure TIG welding Standard torch with one rocker (MG rocker, two torch triggers) Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 BRT 2 = torch trigger 2 Functions mode Operating elements Welding current On/Off Secondary current (factory-set) Secondary current (tapping mode) / (latched mode) Welding current On/Off...
Welding procedure TIG welding 4.1.12.3 Potentiometer torch (8-pole) The welding machine needs to be configured for operation with a potentiometer torch > see 4.1.12.4 chapter. Potentiometer torch with one torch trigger: Diagram Operating Explanation of symbols elements BRT 1 = torch trigger 1 Functions Mode Operating...
Welding procedure TIG welding 4.1.12.4 Configuring the TIG potentiometer torch connection DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed.
Welding procedure TIG welding 4.1.13 Up/down operation in modes 4 and 14 By tapping the relevant torch trigger the current can be roughly adjusted. Holding the torch trigger will cause an infinite adjustment of the welding current. This function is only available when using up/down torches in modes 4 and 14! Figure 4-31 The parameter for setting the reach can be found in the machine configuration...
Welding procedure TIG welding 4.1.14 Alternating current waveforms Selection EXIT Figure 4-32 Display Setting/selection Alternating current waveforms ------- Rectangular (ex works) ------- Trapezoidal ------- Sine AC welding with rectangular current waveform (ex works) Highest energy input Alternating current welding with trapezoidal current waveform An all-rounder, suitable for most applications Alternating current welding with sinusoidal current waveform Low noise level...
Welding procedure TIG welding 4.1.15 Ramp function 4.1.15.1 Foot-operated remote control responsiveness With the foot-operated remote control the welding current can be infinitely adjusted during the welding process. The maximum main current has to be set at the machine before starting to weld. Within the preset range the main current can be set by adjusting the pressure on the pedal.
Welding procedure TIG welding 4.1.15.2 RTF 1 foot-operated remote control Figure 4-35 Symbol Meaning Actuate foot-operated remote control (start welding process) Operate foot-operated remote control (set welding current according to application) Release foot-operated remote control (end welding process) The parameter can be changed in the machine configuration menu > see 4.7 chapter. 099-00T400-EW501 21.10.2016...
Welding procedure TIG welding 4.1.16 Automatic AC frequency Automatic AC frequency can be selected for JOBs 1–7 only. The left stop in the frequency functional sequence is used for activation, displayed as The signal light comes on when the function is activated. The machine control adjusts or sets the AC frequency in relation to the set main current.
Welding procedure TIG welding 4.1.17 AC commutation optimisation The AC commutation assistance function can help to increase process stability when welding materials such as pure aluminium. If half-wave failures should occur during the welding process, the parameter can be increased, counteracting half-wave failures. parameter must first be switched on in the machine configuration menu >...
Welding procedure TIG welding 4.1.20 Expert menu (TIG) The expert menu includes functions and parameters which are either not set on the machine control, or which do not require regular setting. ENTER (Enter the menu) • Keep the control button pressed for 2 s. NAVIGATION (Navigate the menu) •...
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Welding procedure TIG welding Display Setting/selection Expert menu Slope time (main current to secondary current) Slope time (main current to secondary current) Slope time (main current to secondary current) Slope time (main current to secondary current) Amplitude balance activArc parameter Parameter also adjustable after TIG activArc welding is activated.
Welding procedure TIG welding 4.1.21 Aligning the cable resistance To ensure optimum welding properties, the electric cable resistance should be aligned again whenever an accessory component such as the welding torch or the intermediate hose package (AW) has been changed. The resistance value of the cables can be set directly or can be aligned by the power source. In the delivery state the cable resistance is set to the optimum values.
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Welding procedure TIG welding 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle from the welding torch. • Unfasten the tungsten electrode and extract. 2 Configuration • Activate the rotary knob while switching on the welding machine at the same time. •...
Welding procedure MMA welding MMA welding 4.2.1 Welding task selection It is only possible to change the basic parameters when no welding current is flowing and any possible access control is disabled > see 4.5 chapter. The welding task is selected using the buttons on the machine control on the welding machine. Signal lights (LED) display the welding parameter selection.
Welding procedure MMA welding 4.2.2 Hotstart The hot start device ensures that stick electrodes ignite more effectively thanks to a greater hot start current. After selecting the stick electrode, the arc ignites with the hot start current for the preset hot start time and then reverts to the main current (AMP).
Welding procedure MMA welding 4.2.3 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current. This makes it easier to weld large-drop melting electrode types at low current strengths with a short arc in particular. EXIT Figure 4-44 4.2.4...
Welding procedure MMA welding 4.2.6 Pulse welding Pulse welding means that the system switches between two currents periodically with a pulse current (Ipuls), a pulse pause current (IPP), a balance ( ) and a frequency ( ) having been defined first. Figure 4-47 AMP = main current, e.g.
Welding procedure MMA welding 4.2.7 Average value pulse welding Average value pulsing is a variant of pulsing, with the particularity that the power source will always maintain the preset average value. This makes this method especially suitable for welding according to welding procedure specifications.
Welding procedure Filler wire welding Filler wire welding 4.3.1 Configuring the welding machine for mechanical arc fusion welding Before the welding machine is commissioned it has to be configured for mechanical arc fusion welding (cold or hot wire welding). The following basic settings are made in the Expert menu: 1.
Welding procedure Filler wire welding 4.3.2 Function sequences/operating modes The welding current operating mode must be set to latched on the welding machine. The welding current is infinitely adjustable by means of torch triggers 3 and 4 (BRT 3 and BRT 4). Torch trigger 2 (BRT 2) switches the welding current on or off.
Welding procedure Filler wire welding 4.3.2.3 3-cycle operation Figure 4-53 This operating mode differs from non-latched operation in the following ways: • Once the third cycle (current) has started, the wire electrode is fed, corresponding to the welding current, until the welding process ends. 4.3.2.4 Latched mode Figure 4-54...
Welding procedure Power-saving mode (Standby) Power-saving mode (Standby) You can activate the power-saving mode by either pressing the push-button > see 3 chapter for a prolonged time or by setting a parameter in the machine configuration menu (time-controlled power- saving mode ) >...
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Welding procedure Machine configuration menu ENTER NAVIGATION EXIT Figure 4-55 099-00T400-EW501 21.10.2016...
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Welding procedure Machine configuration menu Display Setting/selection Exit the menu Torch configuration menu Set welding torch functions Torch mode (ex works 1) > see 4.1.12 chapter Alternative welding start – tapping start Available from torch mode 11 (welding stop by tapping remains active). ------- Function enabled (ex works) ------- Function disabled Up/down speed...
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Welding procedure Machine configuration menu Display Setting/selection Setting the system of units ------- Units of length in mm, m/min. (metric system) ------- Unit of length in inches, ipm (imperial system) Machine configuration (second part) Settings for machine functions and parameter display Foot-operated remote control ramp function >...
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Welding procedure Machine configuration menu Display Setting/selection Welding current polarity switch (dc+) with TIG DC ------- Polarity switch released ------- Polarity switch blocked; protects the tungsten electrode from being permanently damaged (ex works). Reconditioning pulse (tungsten ball stability) Cleaning effect of the tungsten ball at the end of welding. ------- Function enabled (ex works) ------- Function disabled activArc voltage measuring...
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Welding procedure Machine configuration menu Display Setting/selection Service menu Any changes to the service menu should be agreed with the authorised service personnel. Reset (to factory setting) ------- Disabled (ex works) ------- Reset the values in the machine configuration menu ------ Complete reset of all values and settings Resetting is performed when exiting the menu ( Software version query (example)
Rectifying faults Warnings (power source) 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.
Rectifying faults Error messages (power source) Error messages (power source) A welding machine error is indicated by the collective fault signal lamp (A1) lighting up and an error code (see table) being displayed in the machine control display. In the event of a machine error, the power unit shuts down.
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Rectifying faults Error messages (power source) Error message Possible cause Remedy Err 20 Coolant Check coolant level and refill if necessary • The flow quantity of the torch coolant Check coolant level in the reverse cooler has fallen below the permissible •...
Rectifying faults Resetting welding parameters to the factory settings Resetting welding parameters to the factory settings All customised welding parameters that are stored will be replaced by the factory settings. To reset the welding parameters or machine settings to the factory settings, select parameter in the service menu >...
Appendix A Parameter overview – setting information Appendix A Parameter overview – setting information 6.1.1 TIG welding Parameter Display Setting range Comment TIG/plasma Main current Gas pre-flow time Ignition current AMP% % of main current AMP Start time 0,01 0,00 - 20,0 Up-slope time 20,0...
Appendix A Parameter overview – setting information 6.1.2 MMA welding Parameter Display Setting range Comment Main current Hot start current % of main current AMP (parameter to setting Hot start time 10.0 Arcforce Pulse pause current Pulse current Pulse frequency Pulse balance 099-00T400-EW501 21.10.2016...
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