EWM TIGSPEED OSCILLATION DRIVE 45 COLDWIRE Operating Instructions Manual
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Summary of Contents for EWM TIGSPEED OSCILLATION DRIVE 45 COLDWIRE
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Page 1: Operating Instructions
Operating instructions Wire feed unit tigSpeed oscillation drive 45 coldwire 099-000181-EW501 Observe additional system documents! 30.06.2017... -
Page 2: General Instructions
+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. - Page 3 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 Explanation of icons ........................6 Part of the complete documentation ....................7 3 Intended use ............................
- Page 4 Error messages ..........................44 Resetting welding parameters to the factory settings ..............45 Vent coolant circuit ........................46 8 Technical data ............................47 tigSpeed oscillation drive 45 coldwire ..................47 9 Accessories ............................48 Options ............................48 General accessories ........................48 10 Replaceable parts ..........................
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Page 5: For Your Safety
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. •... -
Page 6: Explanation Of Icons
For your safety Explanation of icons 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 Numerical value – adjustable Correct Menu entry Signal light lights up in green... -
Page 7: Part Of The Complete Documentation
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. -
Page 8: Intended Use
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product. -
Page 9: Machine Description – Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Transport bar Carrying handle Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, additional stickers with information on the replacement parts and JOB lists will be located on the inside. -
Page 10: Rear View
Machine description – quick overview Rear view Item Symbol Description Cooling air outlet Quick connect coupling Shielding gas Connection socket (TIG) Welding current, minus potential Connection socket (12-pole) Welding torch control lead Wire electrode connection Welding torch wire feed Rear view Figure 4-2 Item Symbol Description... -
Page 11: Machine Control – Operating Elements
Machine description – quick overview Machine control – Operating elements Item Symbol Description Mains connection cable > see 5.1.7 chapter Cooling air inlet External wire feed inlet Pre-cut casing inlet for external wire feed. Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply Machine control –... -
Page 12: Machine Control – Concealed Operating Elements
Machine description – quick overview Machine control – Operating elements Item Symbol Description Lid > see 4.3.1 chapter Push-button for switching the wire feed speed display m/min Wire feed speed in meters per minute. Wire feed speed in inch per minute. Display, left Wire feed speed Rotary dial, welding parameter setting... -
Page 13: Operating Elements In The Machine
Machine description – quick overview Machine control – Operating elements Item Symbol Description Signal light, duration of main program P Setting range 0.1 s to 20.0 s (0.1 s increments). Used e.g. in connection with the super pulse function Signal light, wire feed speed of reduced main program (P Signal light, duration of reduced main program P Setting range: 0.1 s to 20.0 s (0.1 s increments). -
Page 14: Design And Function
Design and function Transport and installation Design and function 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 15: In Operation
Design and function Transport and installation 5.1.2.1 In operation Temperature range of the ambient air: • -25 °C to +40 °C Relative air humidity: • Up to 50% at 40 °C • Up to 90% at 20 °C 5.1.2.2 Transport and storage Storage in an enclosed space, temperature range of the ambient air: •... -
Page 16: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.5 Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults in the arc (flickering). Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel. -
Page 17: Stray Welding Currents
Design and function Transport and installation 5.1.5.1 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and electronic devices and cause overheating of components, leading to fire. •... -
Page 18: Tig Cold Wire Welding
Design and function Transport and installation 5.1.6 TIG cold wire welding TIG 450W CW 12POL tigSpeed drive 45 coldwire Tetrix Figure 5-6 5.1.6.1 Legend Shielding gas Welding current (minus potential) Welding current (plus potential, workpiece) Coolant inlet (colour-coded) Coolant outlet (colour-coded) Hose package (HP = hose package) 099-000181-EW501 30.06.2017... -
Page 19: Mains Connection
Design and function Transport and installation Control cable, cold wire (5-pole signal input) Control cable, cold wire (5-pole signal input) hotwire Supply voltage connection (1-phase) Supply voltage connection (3-phase) Welding torch control cable connection (12-pole) Welding torch control cable (12-pole) Wire feeding 5.1.7 Mains connection... -
Page 20: Welding Torch Cooling System
Design and function Transport and installation 5.1.8 Welding torch cooling system Insufficient frost protection in the welding torch coolant! Depending on the ambient conditions, different liquids are used for cooling the welding torch > see 5.1.8.1 chapter. Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components. -
Page 21: Intermediate Hose Package Connection
Design and function Transport and installation 5.1.9 Intermediate hose package connection With this machine series, the earth cable on the intermediate hose package must not be connected to the welding machine or wire feeder! Remove the earth cable or push back into the hose package! Figure 5-8 Item Symbol... -
Page 22: Control Cable Pin Configuration
Design and function Transport and installation 5.1.9.1 Control cable pin configuration Figure 5-9 Output (make contact) for torch trigger input of the power source (floating contact) 5.1.10 Welding torch connection Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. -
Page 23: Control Cable Pin Configuration
Design and function Transport and installation Item Symbol Description Connection socket (12-pole) Welding torch control lead Connection socket (TIG) Welding current, minus potential Quick connect coupling Shielding gas • Extend and lay out the torch hose package. • Insert the wire feed plug of the welding torch into the wire electrode connector and lock by turning to the right. -
Page 24: Open The Protective Flap Of The Wire Feeder
Design and function Transport and installation 5.1.11.1 Open the protective flap of the wire feeder To perform the following steps, the protective flap of the wire feeder needs to be opened. Make sure to close the protective flap again before starting to work. •... -
Page 25: Inching The Wire Electrode
Design and function Transport and installation • Slide new drive rollers into place so that the diameter of the wire used is visible on the drive roller. • Screw the drive rollers in place with knurled screws. Figure 5-13 5.1.11.4 Inching the wire electrode CAUTION Risk of injury due to welding wire escaping from the welding torch! The welding wire can escape from the welding torch at high speed and cause bodily... -
Page 26: Spool Brake Setting
Design and function Transport and installation Item Symbol Description Wire feed nipple Guide tube • Extend and lay out the torch hose package. • Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip upwards). • Unwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe. - Page 27 Design and function Transport and installation Figure 5-16 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve 099-000181-EW501 30.06.2017...
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Page 28: Shielding Gas Volume Settings
Design and function Transport and installation • Place the shielding gas cylinder into the relevant cylinder bracket. • Secure the shielding gas cylinder using a securing chain. • Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight. •... -
Page 29: Gas Test
Design and function Configuring the welding machine for mechanical arc fusion welding 5.1.13.1 Gas test Figure 5-17 5.1.13.2 Purge hose package Figure 5-18 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. The basic settings are configured directly at the welding machine control. -
Page 30: Selection And Adjustment
Design and function Configuring the welding machine for mechanical arc fusion welding 5.2.1 Selection and adjustment To set the welding programs, you can use the machine control. The left hand display shows the wire feed speed, the right hand display shows further parameter settings such as program number or hot wire current (for hotwire only). -
Page 31: Superpuls
Configuring the welding machine for mechanical arc fusion welding 5.2.2 superPuls The two functions superPuls and superimposed forward/backward motion of the wire can not be used simultaneously. The EWM superPuls function enables automatic switching between two operating points in a process. ENTER EXIT Figure 5-20 Display... -
Page 32: Operating Modes (Functional Sequences)
Design and function Configuring the welding machine for mechanical arc fusion welding 5.2.3 Operating modes (functional sequences) Torch trigger 1 (BRT 1) switches the welding current on or off. Torch trigger 2 (BRT 2) switches the wire feeding on or off. In addition, you can inch the wire by pressing torch trigger 2 (BRT 2) or reverse inch the wire by tapping it. -
Page 33: Non-Latched Manual
Design and function Configuring the welding machine for mechanical arc fusion welding 5.2.3.2 Non-latched Manual The welding machine has to be set to a latched operating mode. Figure 5-22 First cycle (current) • Press torch trigger 1 (BRT 1), the gas pre-flow time elapses. •... -
Page 34: Latched Manual
Design and function Configuring the welding machine for mechanical arc fusion welding 5.2.3.3 Latched manual Figure 5-23 This operating mode differs from non-latched operation in the following ways: • Wire feeding is started by pressing and releasing (tapping) BRT 2. •... -
Page 35: Non-Latched Automatic
Design and function Configuring the welding machine for mechanical arc fusion welding 5.2.3.4 Non-latched automatic The welding machine has to be set to a non latched operating mode. Figure 5-24 First cycle (current) • Press torch trigger 1 (BRT 1) and keep pressed. •... -
Page 36: Latched Automatic
Design and function Configuring the welding machine for mechanical arc fusion welding 5.2.3.5 Latched automatic The welding machine has to be set to a latched operating mode. Figure 5-25 1. cycle (current) • Press torch trigger 1 (BRT 1), the gas pre-flow time elapses. •... -
Page 37: Tig Tacking
Design and function Configuring the welding machine for mechanical arc fusion welding 5.2.3.6 TIG tacking The welding machine has to be set to a non latched operating mode. Figure 5-26 Sequence: • Press torch trigger 1 (BRT 1) and keep pressed. •... -
Page 38: Menus And Sub-Menus On The Machine Control
Design and function Access control 5.2.4 Menus and sub-menus on the machine control 5.2.4.1 Direct menus (direct access to parameters) Functions, parameters and their values can be accessed directly, e.g. can be selected by pressing a button once. 5.2.4.2 Expert menu The Expert menu has adjustable parameters stored that don’t require regular setting. -
Page 39: Welding Torch Holder
Design and function Welding torch holder Welding torch holder The item described in the following is part of the machine´s scope of delivery. Figure 5-28 Item Symbol Description Crossmember of the transport handle Torch holder Fan-type lock washers Fixing screws (x 4) •... -
Page 40: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General 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. -
Page 41: Maintenance Work, Intervals
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-000181-EW501 30.06.2017... -
Page 42: Disposing Of Equipment
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives on the Declaration of Conformity on your machine). -
Page 43: 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 44: Error Messages
Rectifying faults Error messages Wire feed problems Unsuitable or worn welding torch equipment Adjust contact tip (cold wire/hot wire) to wire diameter, blow through and replace if necessary Adjust wire guide to material in use, blow through and replace if necessary ... -
Page 45: Resetting Welding Parameters To The Factory Settings
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. Figure 7-1 099-000181-EW501 30.06.2017... -
Page 46: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit 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 7-2 099-000181-EW501 30.06.2017... -
Page 47: Technical Data
Technical data tigSpeed oscillation drive 45 coldwire Technical data tigSpeed oscillation drive 45 coldwire Performance specifications and guarantee only in connection with original spare and replacement parts! Mains voltage (tolerances) 1 x 230 V (–40% to +15%) Frequency 50/60 Hz... -
Page 48: Accessories
Accessories Options Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Options Type Designation Item no. ON WAK tigSpeed Wheel assembly kit with strain relief 092-007927-00000 ON Filter xx5 Dirt filter 092-002662-00000 General accessories Type... -
Page 49: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable 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 50 Replaceable parts Wire feed rollers Figure 10-1 099-000181-EW501 30.06.2017...
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Page 51: Appendix A
Appendix A Setting instructions Appendix A 11.1 Setting instructions The parameter lists below serve as an aid to determine the parameters. The actual parameters to be set depend on the joint and welding position. The welding speed as well depends on the welding task and the parameters set. Figure 11-1 Item Description... -
Page 52: Superpuls Tig Cold Wire Welding
Appendix A Setting instructions Forehand 10– 41-42 Forehand 10– 41-42 Forehand 10– 41-42 Forehand 10– 41-42 Forehand 10– 41-42 11.1.2 superPuls TIG cold wire welding Fillet weld PB position Parent metal: Unalloyed/low-alloy Welding consumable: Unalloyed/low-alloy, Ø 1.0 mm Wf1/tWF1 Wf2/tWF2 Welding Wire angle torch... -
Page 53: Continuous Tig Cold Wire Welding
Appendix A Setting instructions Forehand 10– 41–42 Fillet weld PF position Parent metal: Unalloyed/low-alloy Welding consumable: Unalloyed/low-alloy, Ø 1.0 mm t [mm] Is [A] Hz [1/s] Vs [cm/min] Welding torch Wire angle [°]* (m/min) [°] Forehand 10– 41–42 Forehand 10– 41–42 Forehand 10–... -
Page 54: Superpuls Tig Cold Wire Welding
Appendix A Setting instructions Forehand 10– 41-42 11.1.5 superPuls TIG cold wire welding Fillet weld PB position Parent metal: High-alloy Welding consumable: High-alloy. Ø 1.0 mm Wf1/tWF1 Wf2/tWF2 Welding Wire angle torch [mm] [m/min] [sec] [m/min] [sec] [cm/min] [°] [°] 0.15 0.0/off 0.35... - Page 55 Appendix A Setting instructions Fillet weld PF position Parent metal: High-alloy Welding consumable: High-alloy. Ø 1.0 mm t [mm] Is [A] Hz [1/s] Vs [cm/min] Welding torch Wire angle [°]* (m/min) [°] 13.5 Forehand 10– 41–42 13.5 Forehand 10– 41–42 13.5 Forehand 10–...
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Page 56: Appendix B
Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-000181-EW501 30.06.2017...
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