EWM tigSpeed continuous drive 45 hotwire Operating Instructions Manual
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Summary of Contents for EWM tigSpeed continuous drive 45 hotwire
- Page 1 Operating instructions Wire feed unit tigSpeed continuous drive 45 hotwire 099-000236-EW501 Observe additional system documents! 21.10.2015 Register now and benefit! Jetzt Registrieren und Profitieren! www.ewm-group.com...
- Page 2 +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.
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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 Ambient conditions ....................... - Page 4 Error messages ..........................60 Resetting welding parameters to the factory settings ..............60 Vent coolant circuit ........................61 8 Technical data ............................62 tigSpeed continuous drive 45 hotwire ..................62 9 Accessories ............................63 Options ............................63 General accessories ........................63 10 Replaceable parts ..........................
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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 Special technical points which users must observe. Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine enter the menu ENTER Navigating in the menu NAVIGATION Exit the menu EXIT... -
Page 7: General
Safety instructions General General DANGER Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •... - Page 8 Safety instructions General WARNING Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
- 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 8 Technical data chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
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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: Ambient Conditions
Safety instructions Transport and installation 2.4.1 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 13: Intended Use
Intended use Applications Intended use WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! • The equipment must only be used in line with proper usage and by trained or expert staff! •... -
Page 14: Documents Which Also Apply
3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 15: Machine Description - Quick Overview
Machine description – quick overview System overview Machine description – quick overview System overview The machine described in this manual is integrated into the welding system as shown in the diagram. Figure 4-1 Item Symbol Description Wire feeder with power source (TIG hot wire) Power source (TIG) Observe additional system documents! 099-000236-EW501... -
Page 16: Front View
Machine description – quick overview Front view Front view Figure 4-2 099-000236-EW501 21.10.2015... - Page 17 Machine description – quick overview Front view 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. Wire spool inspection window Check wire supply Slide latch, lock for the protective cap...
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Page 18: Rear View
Machine description – quick overview Rear view Rear view Figure 4-3 099-000236-EW501 21.10.2015... - Page 19 Machine description – quick overview Rear view Item Symbol Description Connector plug, 5-pole Control lead Machine fuse (6,3 A) Main switch, machine on/off Connector plug (TIG) Welding current, minus potential Connection socket (TIG hot wire) Hot wire power, plus potential, workpiece connection Connecting nipple G¼, shielding gas connection Mains connection cable - See 5.6 Mains connection chapter...
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Page 20: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Operating elements that are not listed have no function! Figure 4-4 099-000236-EW501 21.10.2015... - Page 21 Machine description – quick overview Machine control – Operating elements Item Symbol Description Lid - See 4.4.1 Machine control – Concealed operating elements 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.
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Page 22: Machine Control - Concealed Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Concealed operating elements 4.4.1 Figure 4-5 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used. -
Page 23: Operating Elements In The Machine
Machine description – quick overview Machine control – Operating elements 4.4.2 Operating elements in the machine Figure 4-6 Item Symbol Description Wire spool holder Wire feed unit 099-000236-EW501 21.10.2015... -
Page 24: 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 25: Machine Cooling
Design and function Machine cooling 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 26: 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 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 27 Design and function Notes on the installation of welding current leads Use an individual welding lead to the workpiece for each welding machine! Figure 5-2 Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! Always keep leads as short as possible! Lay any excess cable lengths in meanders.
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Page 28: Installation
Design and function Installation Installation WARNING Risk of accident due to improper transport of machines that may not be lifted! Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only! •... -
Page 29: Tig Hot Wire Welding
Design and function Installation 5.5.2 TIG hot wire welding TIG 450W HW 12POL tigSpeed continuous drive 45 hotwire Tetrix Figure 5-5 099-000236-EW501 21.10.2015... -
Page 30: Legend
Design and function Installation 5.5.2.1 Legend Shielding gas Welding current (minus potential) Coolant inlet (colour-coded) Coolant outlet (colour-coded) Hose package (HP = hose package) Welding current (plus potential, workpiece) Control cable, hot wire (signal input, 5-pole) Control cable, hot wire (signal output, 5-pole) hotw ire Supply voltage connection (1-phase) Supply voltage connection (3-phase) -
Page 31: 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 32: Welding Torch Cooling System
Design and function Welding torch cooling system Welding torch cooling system 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 33: Intermediate Hose Package Connection
Design and function Intermediate hose package connection Intermediate hose package connection Figure 5-7 Item Symbol Description Power source Intermediate hose package Connector plug (TIG) Welding current, minus potential Connector plug, 5-pole Control lead Connecting nipple G¼, shielding gas connection Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply... -
Page 34: Control Cable Pin Configuration
Design and function Intermediate hose package connection 5.8.1 Control cable pin configuration Figure 5-8 Output (make contact) for torch trigger input of the power source (floating contact) 099-000236-EW501 21.10.2015... -
Page 35: Connection For Workpiece Lead
Design and function Connection for workpiece lead Connection for workpiece lead The item described in the following is part of the machine´s scope of delivery. Figure 5-9 Item Symbol Description Workpiece Connection socket (TIG hot wire) Hot wire power, plus potential, workpiece connection •... -
Page 36: Welding Torch Connection
Design and function Welding torch connection 5.10 Welding torch connection CAUTION 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 37: Control Cable Pin Configuration
Design and function Welding torch connection Item Symbol Description Connection socket (TIG hot wire) Hot wire power, minus potential Quick connect coupling Shielding gas Connection socket (TIG) Welding current, minus potential • Extend and lay out the torch hose package. •... -
Page 38: Wire Feed
Design and function Wire feed 5.11 Wire feed 5.11.1 Open the protective flap of the wire feeder CAUTION 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 39: Changing The Wire Feed Rollers
Design and function Wire feed 5.11.3 Changing the wire feed rollers Unsatisfactory welding results due to faulty wire feeding! Wire feed rollers must be suitable for the diameter of the wire and the material. • Check the roller label to verify that the rollers are suitable for the wire diameter. Turn or change if necessary! •... -
Page 40: Inching The Wire Electrode
Design and function Wire feed 5.11.4 Inching the wire electrode CAUTION Risk of injury due to moving parts! The wire feeders are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons! • Do not reach into rotating or moving parts or drive components! •... - Page 41 Design and function Wire feed Figure 5-14 Item Symbol Description Adjusting nut Feed roll tensioner Fixing the clamping unit and setting the pressure. Clamping unit Knurled screw Pressure roller Drive roller Wire feed nipple Guide tube • Extend and lay out the torch hose package. •...
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Page 42: Spool Brake Setting
Design and function Wire feed 5.11.5 Spool brake setting Figure 5-15 Item Symbol Description Allen screw Securing the wire spool retainer and adjustment of the spool brake • Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect. Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation! 099-000236-EW501... -
Page 43: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.12 Shielding gas supply (shielding gas cylinder for welding machine) 5.12.1 Connecting the shielding gas supply WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! •... -
Page 44: Gas Test
Design and function Shielding gas supply (shielding gas cylinder for welding machine) Figure 5-16 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 45: Configuring The Welding Machine For Mechanical Arc Fusion Welding
Design and function Configuring the welding machine for mechanical arc fusion welding 5.13 Configuring the welding machine for mechanical arc fusion welding The welding machine must be configured before commissioning for the first time for mechanical arc fusion welding (cold or hot wire welding). The basic settings are configured directly at the welding machine control. -
Page 46: Non-Latched Manual
Design and function Configuring the welding machine for mechanical arc fusion welding 5.13.1.2 Non-latched Manual The welding machine has to be set to a latched operating mode. Figure 5-18 First cycle (current) • Press torch trigger 1 (BRT 1), the gas pre-flow time elapses. •... -
Page 47: Latched Manual
Design and function Configuring the welding machine for mechanical arc fusion welding 5.13.1.3 Latched manual Figure 5-19 This operating mode differs from non-latched operation in the following ways: • Wire feeding is started by pressing and releasing (tapping) BRT 2. •... -
Page 48: Non-Latched Automatic
Design and function Configuring the welding machine for mechanical arc fusion welding 5.13.1.4 Non-latched automatic The welding machine has to be set to a non latched operating mode. Figure 5-20 First cycle (current) • Press torch trigger 1 (BRT 1) and keep pressed. •... -
Page 49: Latched Automatic
Design and function Configuring the welding machine for mechanical arc fusion welding 5.13.1.5 Latched automatic The welding machine has to be set to a latched operating mode. Figure 5-21 1. cycle (current) • Press torch trigger 1 (BRT 1), the gas pre-flow time elapses. •... -
Page 50: Tig Tacking
Design and function Configuring the welding machine for mechanical arc fusion welding 5.13.1.6 TIG tacking The welding machine has to be set to a non latched operating mode. Figure 5-22 Sequence: • Press torch trigger 1 (BRT 1) and keep pressed. •... -
Page 51: Superpuls
Design and function Configuring the welding machine for mechanical arc fusion welding 5.13.1.7 superPuls The EWM superPuls function enables automatic switching between two operating points in a process. ENTER EXIT Figure 5-23 Display Setting/selection Selects superPuls Switches function on or off. -
Page 52: Selection And Adjustment
Design and function Configuring the welding machine for mechanical arc fusion welding 5.13.2 Selection and adjustment Setting the welding programs with the welding machine control Operatin Action Result Display element Press the push-button until signal light flashes. Wire feed speed (left)/program number (right) Select/get program number, e.g. -
Page 53: Menus And Sub-Menus On The Machine Control
Design and function Menus and sub-menus on the machine control 5.14 Menus and sub-menus on the machine control 5.14.1 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. -
Page 54: Protecting Welding Parameters From Unauthorised Access
Design and function Protecting welding parameters from unauthorised access 5.15 Protecting welding parameters from unauthorised access To prevent people from unauthorised or inadvertent changing of the welding parameters at the machine, entering values on the control can be blocked by using the key switch. Key position 1 = All parameters can be set Key position 0 =... -
Page 55: Welding Torch Holder
Design and function Welding torch holder 5.16 Welding torch holder The item described in the following is part of the machine´s scope of delivery. Figure 5-25 Item Symbol Description Crossmember of the transport handle Torch holder Fan-type lock washers Fixing screws (x 4) •... -
Page 56: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER Improper maintenance and testing The equipment may only be cleaned, repaired or tested by specialist, skilled persons! A skilled person is one who, due to training, knowledge and experience, is able to recognise the dangers that can occur during testing of this equipment as well as possible subsequent damage and who is able to implement the required safety procedures. -
Page 57: Monthly Maintenance Tasks
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU). -
Page 58: 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 59 Rectifying faults Checklist for rectifying faults 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 ...
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Page 60: Error Messages
Rectifying faults Error messages Error messages 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. -
Page 61: 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 7-1 099-000236-EW501 21.10.2015... -
Page 62: Technical Data
Technical data tigSpeed continuous drive 45 hotwire Technical data tigSpeed continuous drive 45 hotwire Performance specifications and guarantee only in connection with original spare and replacement parts! Hot wire current setting range 40 A to 180 A Max. hot wire voltage 10 V Duty cycle at 40 °C ambient temperature... -
Page 63: 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 MF XX5 Dirt filter 092-002662-00000 General accessories Type... -
Page 64: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable parts 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 65: Conversion Sets
Replaceable parts Wire feed rollers 10.1.3 Conversion sets Type Designation Item no. URUE VERZ>UNVERZ FE/AL Conversion kit, 37mm, 4-roller drive on non-toothed 092-000415-00000 4R SF rollers (steel/aluminium) URUE AL 4ZR4R 0,8+1,0 SF Conversion kit, 37 mm, 4-roller drive for aluminium 092-002268-00000 URUE AL 4ZR4R 1,0+1,2 SF Conversion kit, 37 mm, 4-roller drive for aluminium... -
Page 66: Setting Instructions
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 67: Continuous Tig Hot Wire Welding
Appendix A Setting instructions 11.1.1 Continuous TIG hot wire welding Fillet weld PB position Parent metal: Unalloyed/low-alloy Welding consumable: Unalloyed/low-alloy, Ø 1.0 mm t [mm] Is [A] Hz [1/s] IH [A] Vs [cm/min] Welding torch Wire angle [°] (m/min) [°] Forehand 10–... -
Page 68: Continuous Tig Hot Wire Welding
Appendix A Setting instructions 11.1.2 Continuous TIG hot wire welding Fillet weld PB position Parent metal: Unalloyed/low-alloy Welding consumable: Unalloyed/low-alloy, Ø 1.0 mm t [mm] Is [A] Hz [1/s] IH [A] Vs [cm/min] Welding torch Wire angle [°] (m/min) [°] Forehand 10–... -
Page 69: Tig Cold Wire Welding With Superpuls
Appendix A Setting instructions 11.1.3 TIG cold wire welding with superPuls 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 [mm] [m/min] [sec] [m/min] [sec] [cm/min] [°] [°] 0.15 0.0/off 0.35 Forehand 15 0.15... -
Page 70: Tig Hot Wire Welding With Superpuls
Appendix A Setting instructions 11.1.4 TIG hot wire welding with superPuls 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 [mm] [m/min] [sec] [m/min] [sec] [cm/min] [°] [°] 0.15 0.0/off 0.35 Forehand 15 0.15... -
Page 71: Continuous Tig Hot Wire Welding
Appendix A Setting instructions 11.1.5 Continuous TIG hot wire welding Fillet weld PB position Parent metal: High-alloy Welding consumable: High-alloy. Ø 1.0 mm t [mm] Is [A] Hz [1/s] IH [A] Vs [cm/min] Welding torch Wire angle [°] (m/min) [°] Forehand 10–... -
Page 72: Continuous Tig Hot Wire Welding
Appendix A Setting instructions 11.1.6 Continuous TIG hot wire welding Fillet weld PB position Parent metal: High-alloy Welding consumable: High-alloy. Ø 1.0 mm t [mm] Is [A] Hz [1/s] IH [A] Vs [cm/min] Welding torch Wire angle [°] (m/min) [°] Forehand 10–... -
Page 73: Tig Cold Wire Welding With Superpuls
Appendix A Setting instructions 11.1.7 TIG cold wire welding with superPuls 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 Forehand 15 0.15... -
Page 74: Tig Hot Wire Welding With Superpuls
Appendix A Setting instructions 11.1.8 TIG hot wire welding with superPuls 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 Forehand 15 0.15... -
Page 75: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-000236-EW501 21.10.2015...
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