Related Manuals for EWM Synergic
Summary of Contents for EWM Synergic
- Page 1 Operating instructions Control Synergic (M3.7X-M) 099-0M37XM-EW501 Observe additional system documents! 16.07.2018...
- 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.
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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 Explanation of icons ........................5 Part of the complete documentation ....................6 3 Intended use ............................ - Page 4 Contents Notes on the use of these operating instructions 5.5.2 Aligning the cable resistance ..................28 5.5.3 Power-saving mode (Standby) ..................29 6 Rectifying faults............................ 30 Display machine control software version ..................30 Error messages (power source) ....................30 Resetting JOBs (welding tasks) to the factory settings ..............31 6.3.1 Resetting a single JOB ....................
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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: Part Of The Complete Documentation
For your safety Part of the complete documentation Symbol Description Symbol Description Time representation (e.g.: wait 4 s / Signal light flashes red actuate) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use 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... -
Page 7: 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 8: 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 9: Control Section A
Machine control – Operating elements Overview of control sections 4.1.1 Control section A Figure 4-2 Item Symbol Description JOB- Welding task push-button (JOB) LIST Select the welding task from the welding task list (JOB-LIST). The list can be found inside the protective cap on the wire feeder and in the appendix to these operating instructions. -
Page 10: 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 4.3.5 chapter. Wire feed speed unit signal light m/min --- Parameter value is displayed in meters per minute. -
Page 11: Welding Data Display
Machine control – Operating elements Welding data display Item Symbol Description JOB number display (welding task) > see 5.2.1 chapter Status display signal light (Hold) Display of mean values across the entire welding process. Percent signal light The displayed value is displayed in percent. Material thickness unit signal light mm ------- Parameter value is displayed in millimeters. -
Page 12: 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) are adopted and that the nominal value for the current (A) is shown in the left-hand welding data display. -
Page 13: Functional Characteristics
Functional characteristics Operating the machine control Functional characteristics 5.1.1 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 14: Wire Thread
Functional characteristics Operating the machine control 5.1.1.3 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 15: Mig/Mag Welding
Functional characteristics MIG/MAG welding MIG/MAG welding 5.2.1 Welding task selection The following steps have to be carried out to select the welding job: • Select basic parameters (material type, wire diameter and shielding gas type) and welding procedures (select and enter JOB number by means of JOB-List > see 7.1 chapter). •... -
Page 16: Welding Power (Operating Point)
Functional characteristics MIG/MAG welding 5.2.1.3 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 17: Arc Dynamics (Choke Effect)
Functional characteristics MIG/MAG welding 5.2.1.6 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 18: Burn-Back
Functional characteristics MIG/MAG welding Display Setting/selection Correction of arc length in start program P START Slope time of start program P to main program P START Slope time of main program P to end program P End-crater current Setting range in percent: depending on main current Setting range, absolute: Imin to Imax. -
Page 19: Automatic Cut-Out
Functional characteristics MIG/MAG welding Tap torch trigger (briefly press and release) Shielding gas is flowing Welding power Wire electrode is being fed Wire creep Wire burn-back Gas pre-flow Gas post-flow Non-latched Latched Special latched Time Start program START Main program End program 5.2.4.2 Automatic cut-out... - Page 20 Functional characteristics MIG/MAG welding Non-latched mode Figure 5-12 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 21 Functional characteristics MIG/MAG welding Latched mode Figure 5-13 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 22 Functional characteristics MIG/MAG welding Latched special Figure 5-14 1st cycle • Press and hold torch trigger. • Shielding gas is flowing (gas pre-flow). • Wire feed motor runs at “wire creep speed”. • Arc ignites when the wire electrode makes contact with the workpiece, welding current is flowing (start program P START 2nd cycle...
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Page 23: Standard Mig/Mag Torch
Functional characteristics MMA welding 5.2.5 Standard MIG/MAG torch The MIG welding torch trigger is essentially used to start and stop the welding process. Operating elements Functions • Torch trigger Start/stop welding 5.2.5.1 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 24: Arcforce
Functional characteristics Special parameters (advanced settings) 5.3.3 Arcforce Figure 5-17 Setting: • Negative values: rutile electrode types • Values at zero: basic electrode types • Positive values: cellulose electrode types 5.3.4 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 25: Selecting, Changing And Saving Parameters
Functional characteristics Special parameters (advanced settings) 5.4.1 Selecting, changing and saving parameters Figure 5-20 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) Tapping start for latched and special latched operation 0 = -------- no 4-cycle inching start 1 = -------- 4-cycle inching start possible (ex works) -
Page 26: Latched/Special-Latched Tap Start (P9)
Functional characteristics Special parameters (advanced settings) 5.4.1.2 Latched/special-latched tap start (P9) In latched – tap start – operating mode it is possible to switch straight to the second step by tapping the torch trigger; it is not necessary for current to be flowing. The welding can be halted by pressing the torch trigger for a second time. -
Page 27: Machine Configuration Menu
Functional characteristics Machine configuration menu Machine configuration menu 5.5.1 Selecting, changing and saving parameters Figure 5-22 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 28: Aligning The Cable Resistance
Functional characteristics Machine configuration menu 5.5.2 Aligning the cable resistance The resistance value of the cables can be set directly or it can be adjusted through the power source. The power source cable resistance value is set to 8 mΩ when delivered. This value corresponds to an earth cable length of 5 m, an intermediate hose package length of 1.5 m and a water-cooled welding torch length of 3 m. -
Page 29: 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 be no more welding wire in the contact tip at this point. -
Page 30: 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 31: Resetting Jobs (Welding Tasks) To The Factory Settings
Expert Expert 2.0 / Expert XQ 2.0 CarExpert / Progress (M3.11) alpha Q / Concept / Basic / Basic S / Synergic / not possible Synergic S / Progress (M3.71) / Picomig 355 c) The error message can only be reset by switching the machine off and on again. - Page 32 Rectifying faults Resetting JOBs (welding tasks) to the factory settings Figure 6-2 099-0M37XM-EW501 16.07.2018...
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Page 33: Job-List
Appendix A JOB-List Appendix A JOB-List Figure 7-1 099-0M37XM-EW501 16.07.2018... -
Page 34: Parameter Overview - Setting Ranges
Appendix B Parameter overview – setting ranges Appendix B Parameter overview – setting ranges 8.1.1 MIG/MAG welding Name Display Setting range Ignition current Correction of arc length in start program P -9,9 START Slope time of start program P to main program P START Slope time of main program P to end program P... -
Page 35: Searching For A Dealer
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" 099-0M37XM-EW501 16.07.2018...
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