Subscribe to Our Youtube Channel
Related Manuals for EWM miniDrive GS
Summary of Contents for EWM miniDrive GS
- Page 1 Operating instructions Intermediate drive unit miniDrive GS miniDrive WS 099-005262-EW501 Observe additional system documents! 22.11.2016...
- 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.
-
Page 3: Table Of Contents
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 Intended use ............................ - Page 4 Wire feed rollers for steel wire ..................33 10.2.2 Wire feed rollers for aluminium wire ................33 11 Appendix A ............................34 11.1 Circuit diagram – cable adapter ....................34 12 Appendix B ............................35 12.1 Overview of EWM branches......................35 099-005262-EW501 22.11.2016...
-
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 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... -
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
Intended use Use and operation solely with the following machines Intended use WARNING Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and standards applicable for use in industry and trade. It may only be used for the welding procedures indicated at the rating plate. -
Page 9: Documents Which Also Apply
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 10: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Connections and operating elements for torch cooling only with correspondent machine versions. Figure 4-1 Item Symbol Description Carrying handle Wire speed rotary dial Infinitely adjustable setting of the wire speed from min. to max. (welding output, one-dial operation) Rotary dial, Arc length correction Arc length correction from -10 V to + 10 V... -
Page 11: Inside View
Machine description – quick overview Inside view Inside view Figure 4-2 Item Symbol Description Slide latch, lock for the protective cap 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 12: 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 13: Machine Cooling
Design and function Transport and installation 5.1.2 Machine cooling Insufficient ventilation results in a reduction in performance and equipment damage. • Observe the ambient conditions! • Keep the cooling air inlet and outlet clear! • Observe the minimum distance of 0.5 m from obstacles! 5.1.3 Workpiece lead, general CAUTION... -
Page 14: Welding Torch Cooling System
Design and function Transport and installation 5.1.4 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 5.1.4.1 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 15: 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 16: Stray Welding Currents
Design and function Transport and installation 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. Figure 5-3 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... -
Page 17: Preparing The Welding System
Design and function Preparing the welding system Preparing the welding system 5.2.1 Switching between Push/Pull and intermediate drive WARNING Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. -
Page 18: Welding Torch Connection
Design and function Welding torch connection 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 19: Hose Package/Intermediate Drive Connection
Design and function Hose package/intermediate drive connection Figure 5-6 Item Symbol Description Welding torch Welding torch hose package Welding torch connection (Euro torch connector) Welding current, shielding gas and torch trigger integrated Quick connect coupling (red) coolant return 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Quick connect coupling (blue) -
Page 20: Wire Feed
Design and function Wire feed Wire feed 5.5.1 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 21: Inching The Wire Electrode
Design and function Wire feed 5.5.3 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 22 Design and function Wire feed Figure 5-8 Item Symbol Description Adjusting nut Clamping unit Pressure roller Drive roller Knurled screw Wire feed nipple Feed roll tensioner Fixing the clamping unit and setting the pressure. • Extend and lay out the torch hose package. •...
-
Page 23: Setting The Operating Point (Welding Output)
Design and function Setting the operating point (welding output) Setting the operating point (welding output) The operating point (welding power) is specified using the MIG/MAG one-knob operation principle, i.e. the user can specify either the welding current, the wire feed speed or the material thickness to define the operating point. -
Page 24: Replacing The Steel Liner In The Hose Package
Design and function Replacing the steel liner in the hose package Replacing the steel liner in the hose package Always make sure the the hose package is straight when replacing the wire guide. Figure 5-9 Item Symbol Description Allen key (size 2.5) Headless screw Threaded hole Steel liner... - Page 25 Design and function Replacing the steel liner in the hose package Figure 5-10 Item Symbol Description Open-ended spanner, SW 11 Crown nut Euro central connection Welding current, shielding gas and torch trigger included • Loosen the crown nut of the liner fastening •...
-
Page 26: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Incorrect maintenance and testing! The machine may be cleaned, repaired and tested by skilled and qualified personnel only. A qualified person is one who, due to their training, knowledge and experience, can detect any hazards and possible consequential damage when checking the machine, and can take the necessary safety measures. -
Page 27: Maintenance Work, Intervals
Maintenance, care and disposal Maintenance work, intervals Maintenance work, intervals Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine. -
Page 28: Annual Test (Inspection And Testing During Operation)
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 29: 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 30: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. 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 7-1 099-005262-EW501... -
Page 31: Technical Data
Technical data miniDrive Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! miniDrive 60 VDC Supply voltage 300 A Max. welding current (100% DC) 400 A Max. welding current (60% DC) 1 m/min–20 m/min Wire feed speed Standard roll installation 1.0 + 1.2 mm (for steel wire) -
Page 32: Accessories
Accessories Remote control / connection cable Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Remote control / connection cable Type Designation Item no. R10 19POL Remote control 090-008087-00000 RG10 19POL 5M 090-008108-00000 Remote control to set the wire speed and welding voltage correction... -
Page 33: Replaceable Parts
Replaceable parts Conversion kit 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 34: Circuit Diagram - Cable Adapter
Appendix A Circuit diagram – cable adapter Appendix A Circuit diagram – cable adapter 11.1 WARNING Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. -
Page 35: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005262-EW501 22.11.2016...
Need help?
Do you have a question about the miniDrive GS and is the answer not in the manual?
Questions and answers