EWM drive 4X IC D HP Operating Instructions Manual
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EWM drive 4X IC D HP Operating Instructions Manual

EWM drive 4X IC D HP Operating Instructions Manual

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drive 4X IC D HP
099-005507-EW501
Observe additional system documents!
13.09.2018

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Summary of Contents for EWM drive 4X IC D HP

  • Page 1 Operating instructions Wire feed unit drive 4X IC D HP 099-005507-EW501 Observe additional system documents! 13.09.2018...
  • 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 5.4.5.1 Setting the operating point (welding output)..........38 5.4.5.2 Welding power (operating point) ..............39 5.4.5.3 Operating point setting via welding current, material thickness or wire feed speed ..................... 39 5.4.5.4 Arc length ......................
  • Page 5 7 Rectifying faults ........................... 93 Checklist for rectifying faults ......................93 Error messages (power source) ....................94 8 Technical data ............................96 drive 4X IC D HP .......................... 96 9 Accessories ............................97 General accessories ........................97 Remote control/connecting and extension cable ................. 97 9.2.1...
  • Page 6 Contents Notes on the use of these operating instructions 099-005507-EW501 13.09.2018...

  • 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

    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! 099-005507-EW501 13.09.2018...

  • Page 11: Declaration Of Conformity

    Intended use Documents which also apply 3.3.2 Declaration of Conformity The labelled product 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 12: 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 4-1 099-005507-EW501 13.09.2018...
  • Page 13 Machine description – quick overview Front view / side view from the right Item Symbol Description Carrying handle Machine control > see 4.4 chapter 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 (blue) Coolant forward flow to the welding torch...

  • Page 14: Inside View From The Right

    Machine description – quick overview Inside view from the right Inside view from the right Figure 4-2 Item Symbol Description Push-button gas test / rinse hose package > see 5.1.7 chapter Wire inching push-button For potential- and gas-free inching of the wire electrode through the hose package to the welding torch.

  • Page 15: Inside View From The Left

    Machine description – quick overview Inside view from the left Inside view from the left Figure 4-3 Item Symbol Description Push-button gas test / rinse hose package > see 5.1.7 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...

  • Page 16: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-4 Item Symbol Description Functional sequence > see 4.4.1 chapter Push-button, welding task selection (JOB) SP1/2/3 - Special JOBs (Phoenix Expert only). Pressing the push-button longer: special JOB selection.

  • Page 17: Functional Sequence

    Machine description – quick overview Machine control – Operating elements Item Symbol Description Rotary knob, welding parameter setting • ----------- Setting the welding task (JOB). With machines of the Phoenix Expert series, welding tasks are selected at the power source control. •...
  • Page 18 Machine description – quick overview Machine control – Operating elements Item Symbol Description Signal light, gas pre-flow time Setting range 0.0 s to 20.0 s Signal light, start program (P START • Wire speed:1% to 200% of the main program P •...

  • Page 19: 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 20 Design and function Transport and installation CAUTION Risk of falling! If the double wire feed unit is not positioned correctly on the holder, it may fall, become damaged and cause injury to persons as a result. • Always position the inner feet of the wire feed unit in the provided recesses! •...

  • Page 21: Welding Torch Cooling System

    All information relates to the total hose package length of the complete welding system and presents exemplary configurations (of components of the EWM product portfolio with standard lengths). A straight kink-free installation is to be ensured, taking into account the max. delivery height.

  • Page 22: Notes On The Installation Of Welding Current Leads

    Design and function Transport and installation 5.1.4 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 23: Stray Welding Currents

    Design and function Transport and installation 5.1.5 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 24: Intermediate Hose Package Connection

    Design and function Transport and installation 5.1.6 Intermediate hose package connection The connection is carried out in the interior of the wire feed unit. The connections must be fed through the opening on the rear and the hose package end must be fastened using the strain relief.

  • Page 25: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function Transport and installation • Insert the end of the hose package through the strain relief of the hose package and lock by turning to the right. • Push the welding current cable socket onto the “welding current connecting plug” and lock by turning to the right.

  • Page 26: Purge Hose Package

    Design and function Welding data display 5.1.7.3 Purge hose package 300s Figure 5-8 Welding data display To the left and right of the control displays are the "Parameter selection" buttons ( ). They are used to select welding parameters to be displayed. Each press of the button advances the display to the next parameter (LEDs next to the button indicate the selection).

  • Page 27: Basic Settings For Operation With Two Wire Feeders (P10)

    Design and function Basic settings for operation with two wire feeders (P10) 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 28: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.4.1 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 29: Wire Feed

    Design and function MIG/MAG welding Item Symbol Description 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 (red) Coolant return from welding torch Quick connect coupling (blue)
  • Page 30 Design and function MIG/MAG welding Standard D300 wire spool holder can be used. Adapters are required when using standardised basket coils (DIN 8559) > see 9 chapter. Figure 5-11 Item Symbol Description Carrier pin For fixing the wire spool Knurled nut For fixing the wire spool •...

  • Page 31: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.4.2.3 Changing the wire feed rollers Figure 5-12 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 32: Inching The Wire Electrode

    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 >...
  • Page 33 Design and function MIG/MAG welding Incorrect contact pressure will cause extensive wear of the wire feed rollers! • With the adjusting nuts of the pressure units set the contact pressure so that the wire electrode is conveyed but will still slip through if the wire spool jams. •...

  • Page 34: Spool Brake Setting

    Design and function MIG/MAG welding A prerequisite for the automatic inching process is the correct preparation of the wire guide, especially in the capillary and wire guide tube area > see 5.4.1 chapter. • 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.

  • Page 35: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.4.3 Definition of MIG/MAG welding tasks This machine series offers user-friendly operation and a multitude of features. • Various welding tasks (JOBs) consisting of welding procedure, material type, wire diameter and shielding gas type have been predefined > see 11.1 chapter. •...

  • Page 36: Welding Type

    Design and function MIG/MAG welding 5.4.4.3 Welding type Different forms of MIG/MAG processes are collectively 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 37: Arc Dynamics (Choke Effect)

    Design and function MIG/MAG welding 5.4.4.7 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 38: Conventional Mig/Mag Welding (Gmaw Non Synergic)

    Design and function MIG/MAG welding 5.4.5 Conventional MIG/MAG Welding (GMAW non synergic) It is only possible to change the JOB number when no welding current is flowing. Wire feed speed and welding voltage can be configured independently in two performance ranges: •...

  • Page 39: Welding Power (Operating Point)

    Design and function MIG/MAG welding 5.4.5.2 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 40: Coldarc / Coldarc Puls

    Design and function MIG/MAG welding 5.4.6 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 5.4.4 chapter you benefit from: •...

  • Page 41: Rootarc/Rootarc Puls

    Design and function MIG/MAG welding 5.4.8 rootArc/rootArc puls Short arc with perfect weld modelling capabilities for effortless gap bridging, especially for root welding Figure 5-29 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion •...

  • Page 42: Operating Modes (Functional Sequences)

    Design and function MIG/MAG welding 5.4.10 Operating modes (functional sequences) There are optimum pre-sets for welding parameters such as gas pre-flow and burn back, etc. for numerous applications (although these can also be changed if required). 5.4.10.1 Explanation of signs and functions Symbol Meaning Press torch trigger...
  • Page 43 Design and function MIG/MAG welding Non-latched mode Figure 5-31 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 44 Design and function MIG/MAG welding Non-latched operation with superpulse Figure 5-32 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 45 Design and function MIG/MAG welding Special, non-latched Figure 5-33 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 46 Design and function MIG/MAG welding Spot welding Figure 5-34 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 47 Design and function MIG/MAG welding Special, non-latched with superpulse Figure 5-35 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 48 Design and function MIG/MAG welding Latched mode Figure 5-36 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 49 Design and function MIG/MAG welding Latched mode with superpulse Figure 5-37 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 50 Design and function MIG/MAG welding Latched with changing welding method (process switching) To activate or set the function > see 5.4.15 chapter. Figure 5-38 1st cycle: • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed"...
  • Page 51 Design and function MIG/MAG welding Latched special Figure 5-39 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 52 Design and function MIG/MAG welding Special latched with changing welding method by tapping (process switching) To activate or set the function > see 5.4.15 chapter. Figure 5-40 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) •...
  • Page 53 Design and function MIG/MAG welding Special latched with changing welding method (process switching) Figure 5-41 1st cycle • 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 54 Design and function MIG/MAG welding Special, latched with superpulse Figure 5-42 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 55: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.4.11 MIG/MAG program sequence ("Program steps" mode) Certain materials, aluminium for example, require special functions for reliable and high-quality welding. In this case, the special latched mode is used with the following programs: • Start program P (avoidance of cold welds at start of seam) START •...

  • Page 56: Mig/Mag Overview Of Parameters

    Design and function MIG/MAG welding 5.4.11.2 MIG/MAG overview of parameters , and P are set as relative programs ex faxtory. They relate to percentages of the wire START feed value of the main program P . These programs can also be set in an absolute manner, if desired (see Setting of special parameter P21).

  • Page 57: Example, Aluminium Tack Welding (Non-Latched Special)

    Design and function MIG/MAG welding 5.4.11.4 Example, aluminium tack welding (non-latched special) Figure 5-47 Basic parameters Welding parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20.0s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 58: Example, Aluminium Welding (Latched Special)

    Design and function MIG/MAG welding 5.4.11.5 Example, aluminium welding (latched special) Figure 5-48 Basic parameters Welding parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20.0s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 59: Example, Visible Seams (Latched Super Pulse)

    Design and function MIG/MAG welding 5.4.11.6 Example, visible seams (latched super pulse) Figure 5-49 Basic parameters Welding parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20.0s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 60: Main Program A Mode

    Design and function MIG/MAG welding 5.4.12 Main program A mode Different welding tasks or positions on a workpiece demand various welding performances (operating points) or welding programs. The following parameters are stored in each of the up to 16 programs: •...

  • Page 61: Selecting Parameters (Program A)

    Design and function MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-50 Example 2: Welding different positions on a workpiece (latched) Figure 5-51 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-52 Up to 16 programs (P...

  • Page 62: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.4.13 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 Other functions are also possible by tapping the torch trigger, depending on the machine type and control configuration >...

  • Page 63: Expert Menu (Mig/Mag)

    Design and function MIG/MAG welding 5.4.15 Expert menu (MIG/MAG) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of parameters shown may be limited, e.g. if a function is deactivated. 5.4.15.1 Selection Figure 5-55 Display Setting/selection Burn-back time >...

  • Page 64: Burn-Back

    Design and function MIG/MAG welding Display Setting/selection Pulse arc welding process (program P The pulse arc welding process can be activated in the end program (P ) with the special non-latched and special latched operating modes. ------- Function activated. ------ Function deactivated. For machine versions with pulsed arc welding procedures only.

  • Page 65: Programme Limit

    Design and function TIG welding 5.4.15.3 Programme limit The JOB-dependent program limit allows you to limit the number of programs that can be selected in the selected JOB to (2...9). This option can be set individually per JOB. In addition, a legacy option to set a "global program limit"...

  • Page 66: Welding Task Selection

    Design and function TIG welding Item Symbol Description • TIG welding: Welding current connection for welding torch Power source • 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 67: Tig Arc Ignition

    Design and function TIG welding 5.5.3 TIG arc ignition 5.5.3.1 Liftarc Figure 5-59 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).

  • Page 68: Operating Modes (Functional Sequences)

    Design and function TIG welding 5.5.4 Operating modes (functional sequences) 5.5.4.1 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 Gas pre-flows Gas post-flows Non-latched Special, non-latched Latched...
  • Page 69 Design and function TIG welding Non-latched mode Figure 5-60 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 70 Design and function TIG welding Latched mode Figure 5-62 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 71 Design and function TIG welding Latched special Figure 5-63 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 72: Tig Program Sequence ("Program Steps" Mode)

    Design and function MMA welding 5.5.5 TIG program sequence ("Program steps" mode) Figure 5-64 Basic parameters Item Meaning/explanation Setting range Gas pre-flow time 0 s to 0.9 s START 0% to 200% Ignition current Duration (start program) 0 s to 20 s Slope duration from P to P 0 s to 20 s...

  • Page 73: Welding Current Setting

    Design and function MMA welding 5.6.1.1 Welding current setting Figure 5-66 5.6.2 Arcforce Figure 5-67 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 74: Parameter Overview

    Design and function Remote control 5.6.5 Parameter overview Figure 5-70 Basic parameters Item Meaning/explanation Setting range Welding current 5 A to maximum welding current Hotstart time 0 to 20 s Hotstart current 0 to 200 % The hotstart current is a percentage based on the welding current selected. Remote control The remote controls are operated via the 19-pole remote control connection socket (analogue) or the 7-pole remote control connection socket (digital), depending on the model.

  • Page 75: Remote Control Connection Socket, 19-Pole

    Design and function Access control 5.8.1 Remote control connection socket, 19-pole Figure 5-71 Signal form Short description Output Connection for PE cable screen Output Reference voltage for potentiometer 10 V (max. 10 mA) Control voltage specification (0 V–10 V) – wire feed speed Input Output Reference potential (0 V)

  • Page 76: Selecting, Changing And Saving Parameters

    Design and function Special parameters (advanced settings) 5.10.1 Selecting, changing and saving parameters Figure 5-72 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"...
  • Page 77 Design and function Special parameters (advanced settings) Display Setting/selection Lat. and sp. lat. tapping start 0 = -------- no latched tapping start (Ex works) 1 = -------- latched tapping start possible One or two-wire feed operation 0 = -------- single operation (Ex works) 1 = -------- dual operation, this unit is the "master"...

  • Page 78: Reset To Factory Settings

    Design and function Special parameters (advanced settings) Display Setting/selection Program settings for relative programs 0 = ------- Combined setting of relative programs possible (ex works). 1 = ------- Individual setting of relative programs possible (ex works). Correction or nominal voltage display 0 = ------- Correction voltage display (ex works).

  • Page 79: Display Mode For Up/Down Welding Torch With One-Digit 7-Segment Display (P3)

    Design and function Special parameters (advanced settings) 5.10.3.3 Display mode for Up/Down welding torch with one-digit 7-segment display (P3) Normal display: • Program mode: Program number • Up/down operation: Welding power (0=minimum current/9=maximum current) Toggling display: • Program mode: Program number and welding procedure (P=pulse/n=not pulse) are toggled •...

  • Page 80: Correction Operation, Threshold Value Setting (P7)

    Design and function Special parameters (advanced settings) 5.10.3.6 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 81: Switching Programs With The Standard Torch Trigger (P8)

    Design and function Special parameters (advanced settings) 5.10.3.7 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 82: Latched/Special-Latched Tap Start (P9)

    Design and function 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 83: Job List Switching (P12)

    Design and function Special parameters (advanced settings) 5.10.3.11 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 84: Lower And Upper Limits Of The Remote Job Changeover Process (P13, P14)

    Design and function Special parameters (advanced settings) By repeating the last two steps, the same source JOB can be copied to multiple target JOBs. If the control does not register any user activity for longer than 5 seconds, the parameter display is shown once more and the copy process is complete.

  • Page 85: Selecting Programs With The Standard Torch Trigger (P17)

    Design and function Special parameters (advanced settings) 5.10.3.15 Selecting programs with the standard torch trigger (P17) Allows you to select a program or switch a program before starting welding. You switch to the next program by tapping the torch trigger. Once the last enabled program is reached, you start again at the beginning.

  • Page 86: Correction Or Nominal Voltage Display (P24)

    Design and function Machine configuration menu 5.10.3.21 Correction or nominal voltage display (P24) When setting the arc correction using the right-hand rotary knob the display will either show the correction voltage +- 9.9 V (ex works) or the absolute nominal voltage. 5.10.3.22 JOB selection in Expert mode (P25) The special parameter P25 can be used to specify whether the special JOBs SP1/2/3 or the welding job selection according to the JOB list can be selected on the wire feeder.

  • Page 87: Machine Configuration Menu

    Design and function Machine configuration menu 5.11 Machine configuration menu ENTER EXIT NAVIGATION Figure 5-79 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 88: Aligning The Cable Resistance

    Design and function Machine configuration menu 5.11.1 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 89: Power-Saving Mode (Standby)

    Design and function 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 90: 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 91: Maintenance Work, Intervals

    A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-005507-EW501 13.09.2018...

  • Page 92: Disposing Of Equipment

    • 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. 099-005507-EW501 13.09.2018...

  • Page 93: 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 94: 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 95 Rectifying faults Error messages (power source) 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 96: Technical Data

    Technical data drive 4X IC D HP Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! drive 4X IC D HP Supply voltage (from the welding machine) 42 VAC Duty cycle at 40° C...

  • Page 97: 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 98: 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 99: 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 100: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List JOB no. Processes Material Diameter [mm] Standard GMAW/pulse G3Si1/G4Si1 100% CO2 Standard GMAW/puls G3Si1/G4Si1 100% CO2 Standard GMAW/puls 100% CO2 G3Si1/G4Si1 Standard GMAW/puls 100% CO2 G3Si1/G4Si1 Standard GMAW/puls 100% CO2 G3Si1/G4Si1 Standard GMAW/puls G3Si1/G4Si1 Ar-82/CO2-18 (M21) Standard GMAW/puls...
  • Page 101 Appendix A JOB-List JOB no. Processes Material Diameter [mm] coldArc/coldArc puls Ar-97,5/CO2-2,5 (M12) CrNi 19 9/1.4316 coldArc/coldArc puls AlMg Ar-100 (I1) coldArc/coldArc puls Ar-100 (I1) AlMg coldArc/coldArc puls Ar-100 (I1) AlSi coldArc/coldArc puls AlSi Ar-100 (I1) coldArc/coldArc puls Ar-100 (I1) Al99 coldArc/coldArc puls Al99...
  • Page 102 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Brazing CuSi Ar-97,5/CO2-2,5 (M12) Brazing CuSi Ar-97,5/CO2-2,5 (M12) Brazing CuSi Ar-100 (I1) Brazing CuSi Ar-100 (I1) Brazing CuSi Ar-100 (I1) Brazing CuSi Ar-100 (I1) Brazing CuAl Ar-97,5/CO2-2,5 (M12) Brazing CuAl Ar-97,5/CO2-2,5 (M12) Brazing CuAl Ar-97,5/CO2-2,5 (M12)
  • Page 103 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Block 2/ JOB10 Block 3/ JOB1 Block 3/ JOB2 Block 3/ JOB3 Block 3/ JOB4 Block 3/ JOB5 Block 3/ JOB6 Block 3/ JOB7 Block 3/ JOB8 Block 3/ JOB9 Block 3/ JOB10 171* pipeSolution G3Si1/G4Si1...
  • Page 104 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Ar-82/CO2-18 (M21) Surfacing G3Si1/G4Si1 Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Ar-100 (I1) 220* coldArc - St/Al ZnAl coldArc - St/Al Ar-100 (I1) 221* ZnAl coldArc - St/Al...
  • Page 105 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Standard GMAW/puls Ar-70/He-30 (I3) NiCr 617 Standard GMAW/puls Ar-70/He-30 (I3) NiCr 617 Standard GMAW/puls Ar-70/He-30 (I3) NiCr 625 Standard GMAW/puls Ar-70/He-30 (I3) NiCr 625 Standard GMAW/puls Ar-70/He-30 (I3) NiCr 625 Standard GMAW/puls NiCr 625 Ar-67,95/He-30/H2-2 / CO2-0,05...
  • Page 106 Appendix A JOB-List JOB no. Processes Material Diameter [mm] forceArc/forceArc puls CrNi 22 9 3a/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 CrNi 25 20/1.4842 Ar-97,5/CO2-2,5 (M12) forceArc/forceArc puls CrNi 22 12/1.4829 Ar-97,5/CO2-2,5 (M12) forceArc/forceArc puls CrNi 22 12/1.4829 Ar-97,5/CO2-2,5 (M12) coldArc/coldArc puls...

  • Page 107: Searching For A Dealer

    Appendix B Searching for a dealer Appendix B 12.1 Searching for a dealer Sales & service parteners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005507-EW501 13.09.2018...

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