Related Manuals for EWM drive 4 Basic
Summary of Contents for EWM drive 4 Basic
- Page 1 Operating instructions Wire feed unit drive 4 Basic drive 4 Basic MMA 099-005401-EW501 Observe additional system documents! 17.06.2014 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
- Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted.
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Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................6 General ............................7 Transport and installation ......................11 2.4.1 Ambient conditions ....................... - Page 4 Error messages (power source) ....................47 Welding parameter calibration ..................... 49 Vent coolant circuit ........................50 8 Technical data............................51 drive 4 Basic ..........................51 9 Accessories ............................52 General accessories ........................52 Remote control/connecting and extension cable ................. 52 9.2.1...
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Page 5: Safety Instructions
Safety instructions Notes on the use of these operating instructions Safety instructions 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. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... -
Page 6: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Press Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER (enter the menu) ENTER NAVIGATION NAVIGATION (Navigating in the menu) EXIT EXIT (Exit the menu) Time display (example: wait 4s/press) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use... -
Page 7: General
Safety instructions General General DANGER Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •... - Page 8 Safety instructions General WARNING Risk of injury due to radiation or heat! Arc radiation results in injury to skin and eyes. Contact with hot workpieces and sparks results in burns. • Use welding shield or welding helmet with the appropriate safety level (depending on the application)! •...
- Page 9 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
- Page 10 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data): Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
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Page 11: Transport And Installation
Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •... -
Page 12: Ambient Conditions
Safety instructions Transport and installation 2.4.1 Ambient conditions CAUTION Installation site! The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work. -
Page 13: Intended Use
Intended use Applications Intended use WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! • The equipment must only be used in line with proper usage and by trained or expert staff! •... -
Page 14: Use And Operation Solely With The Following Machines
351, 401, 451, 551 Basic Basic drive 200C Basic drive 300C Basic drive 4L Basic drive 4 drive 4 Basic drive 4 Basic MMA 099-005401-EW501 17.06.2014... -
Page 15: Documents Which Also Apply
Intended use Documents which also apply Documents which also apply 3.3.1 Warranty NOTE For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"! 3.3.2 Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: •... -
Page 16: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Carrying handle Wire spool inspection window Check wire supply Rotary closure Locking of the protective cap, wire spool Rotary closure Locking of the protective cap, wire feed mechanism Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Machine feet... -
Page 17: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Power source welding current connector plug Welding current connection between power source and wire feeder G¼" connecting nipple, shielding gas connection 19-pole connection socket (analogue) Wire feed unit control lead connection Protective cap Turning mandrel support The wire feeder is placed onto the power source turning mandrel using this support to... -
Page 18: Inside View
Machine description – quick overview Inside view Inside view Figure 4-3 Item Symbol Description Wire spool protective cap Wire spool holder Wire feed unit Lighting, inside In power-saving mode and with MMA or TIG welding, the lighting is switched off. Gas test push-button The welding voltage and wire feed motor remain off while testing and setting the gas flow volume. -
Page 19: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-4 Item Symbol Description Rotary dial, wire speed Wire speed setting Operating mode changeover switch Switching between non-latched and latched operating modes Non-latched operation Latched operation Rotary dial, welding voltage Adjustment of the welding voltage from min. -
Page 20: Design And Function
Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •... -
Page 21: Installation
Design and function Installation CAUTION Damage due to incorrect connection! Accessory components and the power source itself can be damaged by incorrect connection! • Only insert and lock accessory components into the relevant connection socket when the machine is switched off. •... -
Page 22: Welding Torch Cooling System
Design and function Welding torch cooling system Welding torch cooling system CAUTION Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void! • Only use the coolant described in this manual (overview of coolants). •... -
Page 23: Notes On The Installation Of Welding Current Leads
Design and function Notes on the installation of welding current leads Notes on the installation of welding current leads NOTE 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 24 Design and function Notes on the installation of welding current leads NOTE Use an individual welding lead to the workpiece for each welding machine! Figure 5-2 NOTE Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! Always keep leads as short as possible! Lay any excess cable lengths in meanders.
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Page 25: Intermediate Hose Package Connection
Design and function Intermediate hose package connection Intermediate hose package connection Figure 5-4 Item Symbol Description Power source Intermediate hose package Safety belt Intermediate hose package strain relief Power source welding current connector plug Welding current connection between power source and wire feeder G¼"... -
Page 26: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Shielding gas supply (shielding gas cylinder for welding machine) Shielding gas supply (shielding gas cylinder for welding machine) 5.6.1 Gas test • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. •... -
Page 27: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.7.1 Welding torch connection CAUTION Equipment damage due to improperly connected coolant lines! If the coolant lines are not connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. •... - Page 28 Design and function MIG/MAG welding Preparation for connecting welding torches with a plastic core: • Push forward the capillary tube on the wire feed side in the direction of the central connector and remove it there. • Slide plastic core guide tube off the central connector. •...
- Page 29 Design and function MIG/MAG welding Figure 5-7 Item Symbol Description Welding torch Welding torch hose package Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Quick connect coupling (blue) coolant supply Quick connect coupling (red) coolant return 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control...
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Page 30: Wire Feed
Design and function MIG/MAG welding 5.7.2 Wire feed 5.7.2.1 Open the protective flap of the wire feeder CAUTION To perform the following steps, the protective flap of the wire feeder needs to be opened. Make sure to close the protective flap again before starting to work. •... -
Page 31: Changing The Wire Feed Rollers
Design and function MIG/MAG welding 5.7.2.3 Changing the wire feed rollers Figure 5-9 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 Design and function MIG/MAG welding NOTE Unsatisfactory welding results due to faulty wire feeding! The wire feed rollers must be suitable for the diameter of the wire and the material. The wire feed rollers are colour-coded to facilitate distinction (see the Wire feed roller overview table). Wire feed roller overview table Material Diameter...
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Page 33: Inching The Wire Electrode
Design and function MIG/MAG welding 5.7.2.4 Inching the wire electrode CAUTION Risk of injury due to moving parts! The wire feeders are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons! • Do not reach into rotating or moving parts or drive components! •... - Page 34 Design and function MIG/MAG welding Figure 5-10 Item Symbol Description Welding wire Wire feed nipple Guide tube Adjusting nut • Extend and lay out the torch hose package. • Carefully unwind the welding wire from the wire spool and insert through the wire feed nipples up to the wire feed rollers.
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Page 35: Spool Brake Setting
Design and function MIG/MAG welding 5.7.2.5 Spool brake setting Figure 5-11 Item Symbol Description Allen screw Securing the wire spool retainer and adjustment of the spool brake • Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect. NOTE Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation! -
Page 36: Welding Task Selection
Design and function MIG/MAG welding 5.7.3 Welding task selection NOTE Selection of a welding task involves the interaction of the controls on the welding machine and the wire feed unit. After the basic settings are made on the welding machine, the operating point and other parameters can be set on the wire feed unit. Figure 5-12 5.7.3.1 Accessory components for operating point setting... -
Page 37: Standard Mig/Mag Torch
Design and function MIG/MAG welding 5.7.4 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 5.7.5 MIG/MAG special-torches Function specifications and more indepth information can be found in the operating manual for the relevant welding torch! 099-005401-EW501 17.06.2014... -
Page 38: Mma Welding
Design and function MMA welding MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •... -
Page 39: Welding Task Selection
Design and function MMA welding 5.8.2 Welding task selection Figure 5-14 5.8.3 Welding current setting The welding current is normally set using the "Wire speed" rotary dial. Operating Action Result Displays element Welding current is set Setpoint setting 5.8.4 Arcforce Operating Action Result... -
Page 40: Air Arc Gouging
Design and function Air arc gouging Air arc gouging NOTE Please note the relevant documentation of the accessory components. Special electrode holders and carbon electrodes are required for air arc gouging. 5.9.1 Gouging torch and workpiece line connection Figure 5-17 Item Symbol Description Intermediate hose package... -
Page 41: Welding Task Selection
Design and function Air arc gouging 5.9.2 Welding task selection Figure 5-18 5.9.3 Welding current setting The welding current is normally set using the "Wire speed" rotary dial. Operating Action Result Displays element Welding current is set Setpoint setting 099-005401-EW501 17.06.2014... -
Page 42: Remote Control
Design and function Remote control 5.10 Remote control CAUTION Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •... -
Page 43: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER 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 44: Monthly Maintenance Tasks
Maintenance, care and disposal Maintenance work 6.2.2 Monthly maintenance tasks 6.2.2.1 Visual inspection • Casing damage (front, rear and side walls) • Wheels and their securing elements • Transport elements (strap, lifting lugs, handle) • Check coolant tubes and their connections for impurities 6.2.2.2 Functional test •... -
Page 45: Disposing Of Equipment
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC). -
Page 46: 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 47: Error Messages (Power Source)
Rectifying faults Error messages (power source) Error messages (power source) NOTE A welding machine error is indicated by an error code being displayed (see table) on the display on the machine control. In the event of a machine error, the power unit is shut down. The display of possible error numbers depends on the machine version (interfaces/functions). - Page 48 Rectifying faults Error messages (power source) Error Category Possible cause Remedy Error 18 No speedometer signal from Check the connection and particularly the (WF. Sl.) second wire feeder (slave speedometer of the second wire feeder drive) (slave drive). Legend for categories (error reset) a) The error message will disappear once the error has been rectified.
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Page 49: Welding Parameter Calibration
Rectifying faults Welding parameter calibration Welding parameter calibration When differentiating between the welding parameters set on the wire feed unit/remote control and those shown on the welding machine, they can be calibrated easily with this function. ENTER NAVIGATION EXIT 8 9 10 8 9 10 8 9 10 8 9 10... -
Page 50: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit NOTE Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! Figure 7-2 099-005401-EW501... -
Page 51: Technical Data
Technical data drive 4 Basic Technical data NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! drive 4 Basic Supply voltage 42 VAC Maximum welding current at 60% DC 550 A Maximum welding current at 100% DC... -
Page 52: Accessories
Accessories General accessories Accessories NOTE 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 AR/MIX 35L/MIN Manometer pressure regulator 094-000009-00000 AK300 Wire spool adapter K300 094-001803-00001 HOSE BRIDGE Tube bridge... -
Page 53: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable parts CAUTION Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •... -
Page 54: 10.1.1.1 Wire Feed Rollers For Steel, Stainless-Steel And Flux Cored Wires
Replaceable parts Wire feed rollers 10.1.1.1 Wire feed rollers for steel, stainless-steel and flux cored wires Type Designation Item no. FE 4R 0.8 MM/0.03 INCH Drive roll set, 37 mm, universal 092-002770-00008 WHITE FE 4R 1,0 MM/0.04 INCH Drive roll set, 37 mm, universal 092-002770-00010 BLUE FE 4R 1.2 MM/0.045 INCH... -
Page 55: Setting Instructions
Appendix A Setting instructions Appendix A 11.1 Setting instructions Figure 11-1 099-005401-EW501 17.06.2014... -
Page 56: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005401-EW501 17.06.2014...
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