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Summary of Contents for EWM drive 4X IC D EX
- Page 1 Operating instructions Wire feed unit drive 4X IC D EX 099-005598-EW501 Observe additional system documents! 26.01.2018...
- 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 ........................6 Part of the complete documentation ....................7 Safety instructions .......................... - Page 4 Checklist for rectifying faults ......................40 Error messages (power source) ....................41 Vent coolant circuit ........................42 8 Technical data............................43 drive 4X IC D EX .......................... 43 9 Accessories ............................44 General accessories ........................44 Remote control/connecting and extension cable ................. 44 9.2.1...
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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 Correct Numerical value – adjustable Input Signal light lights up in green Navigation... -
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 For your safety Safety instructions WARNING Hazard when interconnecting multiple power sources! If a number of power sources are to be connected in parallel or in series, only a technical specialist may interconnect the sources as per standard IEC 60974-9:2010: Installation and use and German Accident Prevention Regulation BVG D1 (formerly VBG 15) or country-specific regulations.
- Page 9 For your safety Safety instructions CAUTION 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! •...
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Page 10: Transport And Installation
For your safety Transport and installation Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the introduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines. - Page 11 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.
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Page 12: Intended Use
Power sources must have the MM identifier for MULTIMATRIX technology in their model designation. 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! 099-005598-EW501 26.01.2018... -
Page 13: Declaration Of Conformity
Intended use Documents which also apply 3.3.2 Declaration of Conformity The labelled machine complies with the following EC directives in terms of its design and construction: • Low Voltage Directive (LVD) • Electromagnetic Compatibility Directive (EMC) • Restriction of Hazardous Substance (RoHS) In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment –... -
Page 14: Machine Description - Quick Overview
Machine description – quick overview Front view / side view from the right Machine description – quick overview Front view / side view from the right Figure 4-1 099-005598-EW501 26.01.2018... -
Page 15: Inside View From The Right
Machine description – quick overview Inside view from the right Item Symbol Description Carrying handle Machine control, see the relevant control operating instructions Connection socket, 7-pole Connection for peripheral devices with digital interface 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Quick connect coupling (red) Coolant return... -
Page 16: Inside View From The Left
Machine description – quick overview Inside view from the left Item Symbol Description Push-button gas test / rinse hose package > see 5.1.6 chapter Wire inching push-button For potential- and gas-free inching of the wire electrode through the hose package to the welding torch. - Page 17 Machine description – quick overview Inside view from the left Item Symbol Description Push-button gas test / rinse hose package > see 5.1.6 chapter Welding torch function changeover switch (special welding torch required) ----- Welding power infinitely adjustable ---- Change over programs or JOBs Connecting nipple G¼, shielding gas connection Wire spool holder Wire feed unit...
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Page 18: Design And Function
Design and function Transport and installation Design and function WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •... - Page 19 Design and function Transport and installation WARNING Risk of accident due to improper transport of machines that must not be lifted! Do not lift or suspend the machine! The machine can drop and cause injuries! The handles, straps or brackets are suitable for transport by hand only! •...
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Page 20: Welding Torch Cooling System
Design and function Transport and installation Figure 5-1 Item Symbol Description Internal unit feet Holder for wire feed unit Press arbor bracket Recesses for unit feet External casing frame • Set the double wire feed on the holder in such a way that the unit's inner feet are held securely in the recesses provided for them. -
Page 21: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.3 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 22: Stray Welding Currents
Design and function Transport and installation 5.1.4 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 23: Intermediate Hose Package Connection
Design and function Transport and installation 5.1.5 Intermediate hose package connection CAUTION Risk from electrical current! If welding is carried out alternately using different methods and if a welding torch and an electrode holder remain connected to the machine, the open-circuit/welding voltage is applied simultaneously on all cables. -
Page 24: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Transport and installation Item Symbol Description Power source Intermediate hose package G¼" connecting nipple, shielding gas connection Shielding gas supply to the central connection of the second welding torch Quick connect coupling (blue) coolant supply Quick connect coupling (red) coolant return Connector plug, welding current "+"... -
Page 25: Gas Test
Design and function Transport and installation Setting instructions Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11.5 = l/min MIG brazing Wire diameter x 11.5 = l/min MIG welding (aluminium) Wire diameter x 13.5 = l/min (100 % argon) Gas nozzle diameter in mm corresponds to l/min gas throughput Helium-rich gas mixtures require a higher gas volume! The table below can be used to correct the gas volume calculated where necessary:... -
Page 26: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.2.1 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 27 Design and function MIG/MAG welding Figure 5-9 Item Symbol Description Welding torch Welding torch hose package 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Quick connect coupling (blue) Coolant feed...
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Page 28: Wire Feed
Design and function MIG/MAG welding 5.2.2 Wire feed 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 29: Changing The Wire Feed Rollers
Design and function MIG/MAG welding 5.2.2.3 Changing the wire feed rollers Figure 5-11 Item Symbol Description Tommy The tommy is used to secure the closure brackets of the wire feed rollers. Closure bracket The closure brackets are used to secure the wire feed rollers. Feed roll tensioner Fixing the clamping unit and setting the pressure. - Page 30 Design and function MIG/MAG welding Unsatisfactory welding results due to faulty wire feeding! The wire feed rolls must be suitable for the diameter of the wire and the material. The wire feed rolls are colour-coded to facilitate distinction (see the Wire feed roll overview table). When working with a wire diameter of >...
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Page 31: Inching The Wire Electrode
Design and function MIG/MAG welding 5.2.2.4 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 injury including injuries to the face and eyes! •... -
Page 32: Spool Brake Setting
Design and function MIG/MAG welding • The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll tensioner setting nuts depending on the welding consumable used. A table with the setting values can be found on a sticker near the wire drive. Version 1: left hand mounting Version 2: right hand mounting Figure 5-13... -
Page 33: Basic Settings For Operation With Two Wire Feeders (P10)
Design and function MIG/MAG welding 5.2.2.6 Basic settings for operation with two wire feeders (P10) The wire feeder controls are configured ex works for double wire feeder operation. This setting should be checked and corrected, if necessary, should the controls have been reset to the factory settings or in the event of errors. -
Page 34: Welding Task Selection
Design and function TIG welding 5.2.3 Welding task selection For selection of the welding task and for general operation see the relevant Control operating instructions. TIG welding 5.3.1 Welding torch connection TIG welding torches to be connected to a Euro torch connector are available in two versions: •... -
Page 35: Welding Task Selection
Design and function MMA welding • Insert the central plug for the welding torch into the central connector and screw together with crown nut. • Insert the welding current plug of the combi welding torch into the (-) welding current connection socket and lock into place by turning to the right (only in case of a separate welding current connection). -
Page 36: Interfaces For Automation
Design and function Interfaces for automation Interfaces for automation 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: Access Control
Design and function Access control Access control To protect against unauthorised or unintentional adjustment of the welding parameters on the machine, the control input can be locked with the aid of a key switch. In key switch position 1 all functions and parameters can be set without restriction. In key switch position 0 the following functions and parameters cannot be changed: •... -
Page 38: 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 39: Monthly Maintenance Tasks
• Information about returning used equipment or about collections can be obtained from the respective municipal administration office. • In addition to this, returns are also possible throughout Europe via EWM sales partners. 099-005598-EW501 26.01.2018... -
Page 40: 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 41: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) A welding machine error will be signalled by an error code (see table) on the control display. In the event of an error, the power unit shuts down. The display of possible error numbers depends on the machine version (interfaces/functions). •... -
Page 42: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Categories legend (resetting the error) a) The error message will disappear once the error has been rectified. b) The error message can be reset by pressing a push-button: Welding machine control Push-button RC1 / RC2 Expert Expert 2.0 / Expert XQ 2.0 CarExpert / Progress (M3.11) -
Page 43: Technical Data
Technical data drive 4X IC D EX Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! drive 4X IC D EX Supply voltage 42 VAC Maximum welding current at 60% DC 550 A Maximum welding current at 100 % DC... -
Page 44: Accessories
Accessories General accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. DM 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030 AK300 Wire spool adapter K300 094-001803-00001 HOSE BRIDGE UNI... -
Page 45: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable parts Performance specifications and guarantee only in connection with original spare and replacement parts! 10.1 Wire feed rollers 10.1.1 Wire feed rollers for steel wire Type Designation Item no. FE 4R 0.6 MM/0.023 INCH Drive roll set, 37 mm, 4 rolls, V-groove for steel, 092-002770-00006 LIGHT PINK... -
Page 46: 10.1.3 Wire Feed Rollers For Cored Wire
Replaceable parts Wire feed rollers 10.1.3 Wire feed rollers for cored wire Type Designation Item no. FUEL 4R 0.8 MM/0.03 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00008 WHITE/ORANGE flux cored wire FUEL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00010 BLUE/ORANGE... -
Page 47: Searching For A Dealer
Appendix A Searching for a dealer Appendix A 11.1 Searching for a dealer Sales & service parteners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005598-EW501 26.01.2018...
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