EWM LP-XQ Operating Instructions Manual
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EWM LP-XQ Operating Instructions Manual

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Operating instructions
Control
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LP-XQ (M3.7X-J)
099-00LPXQ-EW501
Observe additional system documents!
13.03.2018

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  • Page 1 Operating instructions Control LP-XQ (M3.7X-J) 099-00LPXQ-EW501 Observe additional system documents! 13.03.2018...
  • Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. 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 ............................7 Notes on the use of these operating instructions ................7 Explanation of icons ........................8 Part of the complete documentation ....................9 3 Intended use ............................
  • Page 4 Contents Notes on the use of these operating instructions 5.6.1 Welding task selection ....................41 5.6.1.1 Welding current setting .................. 42 5.6.2 Arcforce......................... 42 5.6.3 Hotstart ......................... 42 5.6.4 Antistick......................... 42 Options (additional components) ....................43 5.7.1 Electronic gas flow control (OW DGC) ................. 43 5.7.2 Wire reserve sensor (OW WRS) ..................
  • Page 5 Contents Notes on the use of these operating instructions 8 Appendix B ............................69 Parameter overview – setting ranges ..................69 8.1.1 MIG/MAG welding ......................69 8.1.2 MMA welding ........................ 69 9 Appendix C ............................70 Searching for a dealer ......................... 70 099-00LPXQ-EW501 13.03.2018...
  • Page 6 Contents Notes on the use of these operating instructions 099-00LPXQ-EW501 13.03.2018...

  • Page 7: 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 8: 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 hold Switch Incorrect / Invalid Turn Numerical value –...

  • Page 9: 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 10: 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 11: Machine Control - Operating Elements

    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 two sections (A, B) to ensure maximum clarity. The setting ranges for the parameter values are summarised in the parameter overview section >...

  • Page 12: Control Section A

    Machine control – Operating elements Overview of control sections 4.1.1 Control section A Figure 4-2 Item Symbol Description Welding task push-button (JOB) • ---------- Pressing the push-button briefly: Fast switching of the available welding procedures in the selected basic parameters (material/wire/gas). •...
  • Page 13 Machine control – Operating elements Overview of control sections Item Symbol Description Correction of arc length click wheel • ----------- Setting the arc length correction > see 5.4.1.7 chapter • ----------- Setting arc dynamics > see 5.4.1.8 chapter • ----------- Setting various parameters values depending on the preselection. The white signal lights (LED) around the rotary knob light up when setting is possible.

  • Page 14: Control Section B

    Machine control – Operating elements Overview of control sections 4.1.2 Control section B Figure 4-3 Item Symbol Description Display left / Lock function push-button Switching the device display between various welding parameters. Signal lamps show the selected parameter. -------- Press for 3 s to put the machine into lock function > see 4.3.4 chapter. Wire feed speed unit signal light m/min --- Parameter value is displayed in meters per minute.
  • Page 15 Machine control – Operating elements Overview of control sections Item Symbol Description Motor current signal light During wire inching, the current motor current (wire feed mechanism) is displayed in amperes. Display right - Primary display of welding voltage This display shows the welding voltage, arc length correction, programs or welding power (switching by Display right push-button).

  • Page 16: Welding Data Display

    Machine control – Operating elements Welding data display Welding data display On the left and right of the parameter displays there are push-buttons for the selection of parameters. They are used to select the welding parameters to be displayed and their values. Each time one the button is clicked, the display proceeds to the next parameter (signal lights indicate the selection).

  • Page 17: Operating The Machine Control

    Machine control – Operating elements Operating the machine control Operating the machine control 4.3.1 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.

  • Page 18: Functional Characteristics

    Functional characteristics Shielding gas volume settings Functional characteristics Shielding gas volume settings If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause pores to form. Adjust the shielding gas quantity to suit the welding task! •...

  • Page 19: Wire Thread

    Functional characteristics Wire thread Wire thread The wire inching function is used for potential- and gas-free inching of the wire electrode after the wire spool change. By pressing and holding the wire inching button for a long time, the wire inching speed increases in a ramp function (special parameter P1 >...

  • Page 20: Mig/Mag Welding

    Functional characteristics MIG/MAG welding MIG/MAG welding 5.4.1 Welding task selection Zur Schweißaufgabenanwahl sind folgende Schritte durchzuführen: • Grundparameter (Materialart, Drahtdurchmesser und Schutzgasart) und Schweißverfahren wählen (JOB-Nummer anhand JOB-List > see 7.1 chapter wählen und eingeben). • Betriebs- und Schweißart wählen •...

  • Page 21: Operating Mode

    Functional characteristics MIG/MAG welding 5.4.1.3 Operating mode The operating mode determines the process sequence controlled by the welding torch. Detailed descriptions of the operating modes > see 5.4.4 chapter. Figure 5-7 5.4.1.4 Welding type Different forms of MIG/MAG processes are referred to as welding type. Standard (Welding with standard arc) Depending on the set combination of wire feed speed and arc voltage, the arc types short arc, transitional arc or spray arc can be used for welding.

  • Page 22: Welding Power (Operating Point)

    Functional characteristics MIG/MAG welding 5.4.1.5 Welding power (operating point) The welding power is adjusted according to the principle of one-knob operation. The user can set their operating point optionally as wire feed speed, welding current or material thickness. The optimum welding voltage for the operating point is calculated and set by the welding machine.

  • Page 23: Arc Dynamics (Choke Effect)

    Functional characteristics MIG/MAG welding 5.4.1.8 Arc dynamics (choke effect) This function can be used to adjust the arc between a narrow, hard arc with deep penetration (positive values) and a wide and soft arc (negative values). In addition, the selected settings are displayed with signal lights below the rotary knobs.
  • Page 24 Functional characteristics MIG/MAG welding The user can change the main program welding parameters using the following components. M3.7 – I/J Wire feeder control P1-15 PC 300.NET Software P1-15 MT Up/Down Welding torch P1-9 MT 2 Up/Down Welding torch P1-15 MT PC 1 Welding torch P1-15 MT PC 2...

  • Page 25: Program Sequence

    Functional characteristics MIG/MAG welding Example 2: Welding different positions on a workpiece (latched) Figure 5-14 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-15 Up to 16 programs (P to P ) can be defined. An operating point (wire speed, arc length correction, dynamics/choke effect) can be defined permanently in each program.

  • Page 26: Operating Modes (Functional Sequences)

    Functional characteristics MIG/MAG welding 5.4.4 Operating modes (functional sequences) 5.4.4.1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger (press briefly and release) Shielding gas flowing Welding output Wire electrode is being conveyed Wire creep Wire burn-back Gas pre-flows...
  • Page 27 Functional characteristics MIG/MAG welding Non-latched mode Figure 5-17 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 28 Functional characteristics MIG/MAG welding Special, non-latched Figure 5-18 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P for the time t START...
  • Page 29 Functional characteristics MIG/MAG welding Spot welding Figure 5-19 The ignition time t must be added to the spot time t start 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed" •...
  • Page 30 Functional characteristics MIG/MAG welding Latched mode Figure 5-20 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 31 Functional characteristics MIG/MAG welding Latched special Figure 5-21 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P START Step 2...
  • Page 32 Functional characteristics MIG/MAG welding Special latched with changing welding method by tapping (process switching) To activate or set the function . Figure 5-22 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed" •...

  • Page 33: Forcearc / Forcearc Puls

    Functional characteristics MIG/MAG welding 5.4.5 forceArc / forceArc puls Heat-reduced, directionally-stable and powerful arc with deep fusion penetration for the upper power range. Figure 5-23 • Smaller included angle due to deep penetration and directionally stable arc • Excellent root and sidewall fusion •...

  • Page 34: Wiredarc

    (molten metal) decreases and the penetration reduces. Figure 5-24 With the EWM wiredArc arc with wire control, the welding current (AMP) changes with the change of the stick-out only slightly. The compensation of the welding current takes place with an active control of wire feed speed (DG).

  • Page 35: Coldarc / Coldarc Puls

    Functional characteristics MIG/MAG welding 5.4.8 coldArc / coldArc puls Heat-reduced, low-spatter short arc for high dimensional stability welding and brazing of thin metal sheets with excellent gap-bridging. Figure 5-27 After selecting the coldArc process > see 5.4.1 chapter you benefit from: •...

  • Page 36: 5.4.10.2 Switching Between Push/Pull And Intermediate Drive

    Functional characteristics TIG welding 5.4.10.2 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 37: Tig Arc Ignition

    Functional characteristics TIG welding 5.5.2 TIG arc ignition 5.5.2.1 Liftarc Figure 5-31 The arc is ignited on contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch trigger (liftarc current flowing, regardless of the main current set). b) Incline the torch over the torch gas nozzle to produce a gap of approx.

  • Page 38: Operating Modes (Functional Sequences)

    Functional characteristics TIG welding 5.5.3 Operating modes (functional sequences) 5.5.3.1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger (press briefly and release) Shielding gas flowing Welding output Gas pre-flows Gas post-flows Non-latched Special, non-latched Latched Special, latched...
  • Page 39 Functional characteristics TIG welding Non-latched mode Figure 5-32 Selection • Select non-latched operating mode Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). The arc is ignited using liftarc. • Welding current flows with pre-selected setting. Step 2 •...
  • Page 40 Functional characteristics TIG welding Latched mode Figure 5-34 Selection • Select latched operating mode Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) The arc is ignited using liftarc. • Welding current flows with pre-selected setting. Step 2 •...

  • Page 41: Mma Welding

    Functional characteristics MMA welding Latched special Figure 5-35 Selection • Select latched special mode Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). The arc is ignited using liftarc. • Welding gas flows at pre-selected setting in start program "P ".

  • Page 42: Welding Current Setting

    Functional characteristics MMA welding 5.6.1.1 Welding current setting Figure 5-37 5.6.2 Arcforce Figure 5-38 Setting: • Negative values: rutile electrode types • Values at zero: basic electrode types • Positive values: cellulose electrode types 5.6.3 Hotstart The function hot start ensures a secure igniting of the arc and a sufficient heating to the still cold parent metal at the beginning of the welding process.

  • Page 43: Options (Additional Components)

    Functional characteristics Options (additional components) Options (additional components) 5.7.1 Electronic gas flow control (OW DGC) The connected gas line has to have a preset pressure of 3–5 bar. The electronic gas flow control (DGC) regulates the optimum gas flow rate for the respective welding process (optimally preset from the factory).

  • Page 44: 5.10.1 Selecting, Changing And Saving Parameters

    Functional characteristics Special parameters (advanced settings) 5.10.1 Selecting, changing and saving parameters Figure 5-41 099-00LPXQ-EW501 13.03.2018...
  • Page 45 Functional characteristics Special parameters (advanced settings) Display Setting/selection Wire inching / wire return ramp time 0 = -------- normal inching (10 s ramp time) 1 = -------- fast inching (3 s ramp time) (ex works) Block program "0" 0 = -------- P0 enabled (Ex works) 1 = -------- P0 blocked Display mode for Up/Down welding torch with one-digit 7-segment display (two keys)

  • Page 46: Ramp Time For Wire Inching (P1)

    Functional characteristics Special parameters (advanced settings) Display Setting/selection Block JOB mode 0 = ------- Block JOB mode not enabled (Ex works) 1 = ------- Block JOB mode enabled Program selection with standard torch trigger 0 = ------- no program selection (Ex works) 1 = ------- program selection possible Mean value display for superPuls 0 = ------- Function switched off.

  • Page 47: Program "0", Releasing The Program Block (P2)

    Functional characteristics Special parameters (advanced settings) 5.10.1.2 Program "0", releasing the program block (P2) The program P0 (manual setting) is blocked. Only operation with P1-P15 is possible, irrespective of the key switch position. 5.10.1.3 Display mode for Up/Down welding torch with one-digit 7-segment display (P3) Normal display: •...

  • Page 48: Correction Operation, Threshold Value Setting (P7)

    Functional characteristics Special parameters (advanced settings) 5.10.1.6 Correction operation, threshold value setting (P7) The correction operation is switched on and off for all JOBs and their programs at the same time. A correction operation is specified for wire speed (DV) and welding voltage correction (Ukorr) for each JOB. The correction value is saved separately for each program.

  • Page 49: Switching Programs With The Standard Torch Trigger (P8)

    Functional characteristics Special parameters (advanced settings) 5.10.1.7 Switching programs with the standard torch trigger (P8) Special latched (latched absolute program sequence) • Cycle 1: absolute program 1 is run • Cycle 2: absolute program 2 is run after completion of "tstart". •...

  • Page 50: Latched/Special-Latched Tap Start (P9)

    Functional characteristics Special parameters (advanced settings) The number of programs (P ) corresponds to the cycle number specified under N cycle. 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". •...

  • Page 51: Job List Switching (P12)

    Functional characteristics Special parameters (advanced settings) 5.10.1.11 JOB list switching (P12) Value Name Explanation Task-based JOB numbers are sorted by welding wires and shielding gases. When JOB list selecting, the JOB numbers may be skipped. Real JOB list JOB numbers correspond to the actual memory cells. Every job can be selected, there will be no memory cells if the selection will be skipped.

  • Page 52: Block Job Mode (P16)

    Functional characteristics Special parameters (advanced settings) 5.10.1.14 Block JOB mode (P16) The following accessory components support block JOB mode: • Up/Down welding torch with one-digit 7-segment display (two keys) Program 0 is always active in JOB 0 and program 1 in all other JOBs In this operating mode, a total of 27 JOBs (welding tasks) divided into three blocks can be called up using accessory components.

  • Page 53: Predefined Execution Of The Pulsed Arc Welding Process In The Pa Program (P20)

    Functional characteristics Special parameters (advanced settings) 5.10.1.17 Predefined execution of the pulsed arc welding process in the PA program (P20) For machine versions with pulsed arc welding procedures only. Function active (P20 = 1) • If the superPuls and welding process switching functions are available and activated, the pulse arc welding process is always executed in the main program PA (ex factory).

  • Page 54: 5.10.2 Reset To Factory Settings

    Functional characteristics Machine configuration menu 5.10.2 Reset to factory settings All special parameters saved by the user will be overwritten by the factory settings! Figure 5-45 5.11 Machine configuration menu 5.11.1 Selecting, changing and saving parameters Changes to the welding parameters are only possible if the key switch is set to key position If the Xbutton function is activated, the key switch function is deactivated (see corresponding operating instructions "Control").
  • Page 55 Functional characteristics Machine configuration menu Figure 5-46 Display Setting/selection Lead resistance 1 Lead resistance for the first welding circuit 0 mΩ–60 mΩ (8 mΩ ex works). Lead resistance 2 Lead resistance for the second welding circuit 0 mΩ–60 mΩ (8 mΩ ex works). Only qualified service personnel may change the parameters! Only qualified service personnel may change the parameters! Time-based power-saving mode >...

  • Page 56: 5.11.2 Aligning The Cable Resistance

    Functional characteristics Machine configuration menu 5.11.2 Aligning the cable resistance The resistance value of cables can either be set directly or it can be aligned using the power source. The factory setting of the power sources is 8 mΩ. This value correponds to a 5 m earth cable, a 1.5 m intermediate hose package and a 3 m water-cooled welding torch.

  • Page 57: Power-Saving Mode (Standby)

    Functional characteristics Machine configuration menu 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle from the welding torch. • Trim the welding wire so that it is flush with the contact tip. • Retract the welding wire a little (approx. 50 mm) on the wire feeder. There should now be no more welding wire in the contact tip.

  • Page 58: Rectifying Faults

    Rectifying faults Display machine control software version 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 Error messages (power source) Category Error Possible cause Remedy Fuse failure F3 (4A) on printed Inform the service circuit board VB xx0 Shielding gas No shielding gas Check shielding gas supply error Pre-pressure too low Remove kinks in the hose package;...

  • Page 60: Warnings

    Rectifying faults Warnings Category Error Possible cause Remedy Slave Wire feeder fault (slave drive) Check connectors, cables, connections tachometer error Permanent overload of the wire Do not place liner in tight radii; drive (slave drive) check wire core for smooth movement Short circuit Check welding circuit for short...

  • Page 61: 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 All customised welding parameters that are stored will be replaced by the factory settings. 6.4.1 Resetting a single JOB Figure 6-1 6.4.2 Resetting all JOBs JOBs 1–128 and 170–256 will be reset.

  • Page 62: Job-List

    Appendix A JOB-List Appendix A JOB-List JOB no. Processes Material Diameter [mm] Standard GMAW G3Si1 / G4Si1 100% CO2 Standard GMAW G3Si1 / G4Si1 100% CO2 Standard GMAW G3Si1 / G4Si1 100% CO2 Standard GMAW G3Si1 / G4Si1 100% CO2 Standard GMAW G3Si1 / G4Si1 100% CO2...
  • Page 63 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Standard GMAW / puls CrNi 22 9 3 / 1.4462 Ar-78 / He-20 / CO2-2 (M12) coldArc / coldArc puls CrNi 19 9 / 1.4316 Ar-97,5 / CO2-2,5 (M12) coldArc / coldArc puls CrNi 19 9 / 1.4316 Ar-97,5 / CO2-2,5 (M12) coldArc / coldArc puls...
  • Page 64 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Standard GMAW / puls CuSi Ar-97,5 / CO2-2,5 (M12) Standard GMAW / puls CuSi Ar-97,5 / CO2-2,5 (M12) Standard GMAW / puls CuAl Ar-100 (I1) Standard GMAW / puls CuAl Ar-100 (I1) Standard GMAW / puls CuAl Ar-100 (I1)
  • Page 65 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Block 2/ JOB2 Block 2/ JOB3 Block 2/ JOB4 Block 2/ JOB5 Block 2/ JOB6 Block 2/ JOB7 Block 2/ JOB8 Block 2/ JOB9 Block 2/ JOB10 Block 3/ JOB1 Block 3/ JOB2 Block 3/ JOB3 Block 3/ JOB4 Block 3/ JOB5...
  • Page 66 Appendix A JOB-List JOB no. Processes Material Diameter [mm] rootArc / rootArc puls G3Si1 / G4Si1 Ar-82 / CO2-18 (M21) coldArc - Mg/Mg Ar-70 / He-30 (I3) coldArc - Mg/Mg Ar-70 / He-30 (I3) Rutile/basic flux cored FCW CrNi - Rutile CO2-100 (C1) wire Rutile/basic flux cored...
  • Page 67 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Metal flux-cored wire High tensile steels / Ar-82 / CO2-18 (M21) Special Basic flux-cored FCW Steel - Basic Ar-82 / CO2-18 (M21) Auftragschweißen NiCr 6617 / 2.4627 Ar-70 / He-30 (I3) Auftragschweißen NiCr 6617 / 2.4627 Ar-70 / He-30 (I3)
  • Page 68 Appendix A JOB-List JOB no. Processes Material Diameter [mm] forceArc / forceArc puls CrNi 22 9 3 / 1.4462 Ar-97,5 / CO2-2,5 (M12) forceArc / forceArc puls CrNi 22 9 3 / 1.4462 Ar-97,5 / CO2-2,5 (M12) forceArc / forceArc puls CrNi 25 20 / 1.4842 Ar-97,5 / CO2-2,5 (M12) forceArc / forceArc puls...

  • Page 69: Appendix B

    Appendix B Parameter overview – setting ranges Appendix B Parameter overview – setting ranges 8.1.1 MIG/MAG welding Name Darstellung Einstellbereich Spannungskorrektur Drahtgeschwindigkeit, absolut (Hauptprogramm P m/min 0,00 - 20,0 Gas-Sollwert (Option GFE) l/min 30,0 8.1.2 MMA welding Name Darstellung Einstellbereich Arcforce 099-00LPXQ-EW501 13.03.2018...

  • Page 70: Appendix C

    Appendix C Searching for a dealer Appendix C Searching for a dealer Sales & service parteners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-00LPXQ-EW501 13.03.2018...

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