Inverter tig dc welding machines from 150a – 300a
portable (49 pages)
Summary of Contents for EWM LP-XQ
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Operating instructions Control LP-XQ (M3.7X-N) 099-5TLPXQ-EW501 Observe additional system documents! 29.01.2021...
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+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. No other form of liability, regardless of type, shall be accepted.
Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................6 Notes on using these operating instructions ................6 Explanation of icons ....................... 7 Safety instructions ........................8 Transport and installation ....................11 3 Intended use ..........................
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Contents Notes on using these operating instructions 5.2.16.2 Switching between Push/Pull and intermediate drive ......44 TIG welding .......................... 44 5.3.1 Welding task selection ..................44 5.3.1.1 Welding current setting ................44 5.3.2 Arc ignition ......................45 5.3.2.1 Liftarc ..................... 45 5.3.3 Operating modes (functional sequences) .............
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Contents Notes on using these operating instructions 6 Rectifying faults ........................... 65 Display machine control software version ................65 Error messages (power source) ..................65 Warnings ..........................68 Resetting JOBs (welding tasks) to the factory settings ............69 6.4.1 Resetting a single JOB ..................69 6.4.2 Resetting all JOBs ....................
For your safety Notes on using these operating instructions For your safety Notes on using 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. •...
For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the u- Activate and release / Tap / Tip ser must observe. Switch off machine Release Switch on machine Press and hold Switch Incorrect / Invalid Turn Correct / Valid...
For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •...
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For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
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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! •...
For your safety Transport and installation CAUTION 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 int- roduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines.
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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.
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 stand- ards applicable for use in industry and trade. It may only be used for the welding proce- dures indicated at the rating plate.
Intended use Part of the complete documentation Part of the complete documentation This document is 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.
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 >...
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 pushbutton briefly: Fast switching of the available welding proce- dures in the selected basic parameters (material/wire/gas). •...
Machine control – Operating elements Overview of control sections Item Symbol Description Correction of arc length with click wheel • ----------- Setting the correction of arc length > see 5.2.5.2 chapter • ----------- Setting the arc dynamics > see 5.2.5.3 chapter •...
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Machine control – Operating elements Overview of control sections Item Symbol Description Welding current signal light Display of the welding current in amperes. Signal light, Wire speed Lights when the wire speed is shown on the display. Lock function signal light Use display left / lock function push-button to switch on and off.
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).
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 com- pleted. 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.
Machine control – Operating elements Operating the machine control 4.3.5 JOB favourites Favourites are additional locations for storing and loading frequently used welding tasks, programs and their settings. The status of the Favourites (loaded, changed, not loaded) is indicated by signal lights. •...
Machine control – Operating elements Operating the machine control 4.3.5.3 Deleting saved Favourites Figure 4-8 • Press and hold the favourite memory push-button. After 2 seconds, the signal light of the favourite status turns green after another 5 s, the signal light starts flashing red after another 5 s the signal light goes out •...
Functional characteristics Shielding gas supply (shielding gas cylinder for welding machine) Functional characteristics Shielding gas supply (shielding gas cylinder for welding machine) 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.
Functional characteristics MIG/MAG welding MIG/MAG welding 5.2.1 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 in- creases in a ramp function (special parameter P1 >...
Functional characteristics MIG/MAG welding 5.2.3 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). •...
Functional characteristics MIG/MAG welding 5.2.4.1 Welding procedure After setting the basic parameters you can switch between the welding procedures MIG/MAG, forceArc, wiredArc, rootArc und coldArc (if there is a corresponding combination of the basic parameters). The pro- cess change will also change the JOB number, but the basic parameters remain unchanged. Figure 5-6 5.2.4.2 Operating mode...
Functional characteristics MIG/MAG welding 5.2.4.3 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.
Functional characteristics MIG/MAG welding 5.2.5 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.
Functional characteristics MIG/MAG welding 5.2.5.2 Arc length When required, the arc length (welding voltage) can be adjusted for the welding task in hand by +/– 9.9 V. Figure 5-10 5.2.5.3 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).
Functional characteristics MIG/MAG welding 5.2.7 Programs (P 1-15) Different welding jobs or positions on a workpiece require different welding programs (operating points). The following parameters are stored in each program: • Wire feed speed and voltage correction (welding power) • Operating mode, welding type and dynamic 5.2.7.1 Selection and adjustment...
Functional characteristics MIG/MAG welding Example 2: Welding different positions on a workpiece (latched) Figure 5-15 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-16 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.
Functional characteristics MIG/MAG welding 5.2.8 Operating modes (functional sequences) 5.2.8.1 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...
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Functional characteristics MIG/MAG welding Non-latched mode 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 flows. •...
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Functional characteristics MIG/MAG welding Special, non-latched Figure 5-19 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...
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Functional characteristics MIG/MAG welding Spot welding Figure 5-20 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" •...
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Functional characteristics MIG/MAG welding Latched mode 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 flows. •...
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Functional characteristics MIG/MAG welding Latched special Figure 5-22 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...
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Functional characteristics MIG/MAG welding Special latched with changing welding method by tapping (process switching) To activate or set the function > see 5.2.9 chapter. Figure 5-23 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) •...
Functional characteristics MIG/MAG welding 5.2.9 Expert menu (MIG/MAG) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of pa- rameters shown may be limited, e.g. if a function is deactivated. Figure 5-24 Display Setting/selection Ignition current Setting range in percent: depending on main current Setting range, absolute: Imin to Imax.
Functional characteristics MIG/MAG welding Display Setting/selection End current time (duration of end current) Burn-back time > see 5.2.10 chapter • ---------- Increase value > increase wire burn-back • ---------- Decrease value > decrease wire burn-back 5.2.10 Burn-back The wire burn-back parameter prevents the sticking of the wire electrode in the weld pool or at the contact tip at the end of the welding process.
(molten metal) decreases and the penetration reduces. Figure 5-27 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).
Functional characteristics MIG/MAG welding 5.2.14 coldArc XQ / coldArc puls XQ Heat-reduced, low-spatter short arc for high dimensional stability welding and brazing of thin metal sheets with excellent gap-bridging. Figure 5-29 After selecting the coldArc process > see 5.2.3 chapter you benefit from: •...
Functional characteristics TIG welding 5.2.16.2 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. •...
Functional characteristics TIG welding 5.3.2 Arc ignition 5.3.2.1 Liftarc Figure 5-33 The arc ignites through contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip against the workpiece (lift arc current flows independent of the set main current) b) Angle the torch above the torch gas nozzle until the distance between electrode tip and workpiece is approx.
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Functional characteristics TIG welding Non-latched mode Figure 5-34 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 •...
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Functional characteristics TIG welding Latched mode Figure 5-36 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 •...
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Functional characteristics TIG welding Latched special Figure 5-37 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 ".
Functional characteristics Options (additional components) 5.4.3 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. The ignition takes place here with increased current (hot start current) over a certain time (hot start time).
Functional characteristics Access control Access control To prevent people from unauthorised or inadvertent changing of the welding parameters at the machine, entering values on the control can be blocked by using the key switch. With the key switch in position , all functions and parameters can be configured without any restriction.
Functional characteristics Machine configuration menu Machine configuration menu 5.8.1 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").
Functional characteristics Machine configuration menu 5.8.2 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 inter- mediate hose package and a 3 m water-cooled welding torch.
Functional characteristics Power-saving mode (Standby) 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.
Functional characteristics Special parameters (advanced settings) 5.10.1 Selecting, changing and saving parameters Figure 5-45 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"...
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Functional characteristics Special parameters (advanced settings) Display Setting/selection Correction operation, threshold value setting 0 = ------- correction operation switched off (Ex works) 1 = ------- correction operation on "Main program (PA)" flashing Program switching with standard welding torch No program switching (factory setting) 1 = ------- Special latched 2 = ------- Special latched (n-cycle active) 3 = ------- Special latched (n-cycle sequence from any program)
Functional characteristics Special parameters (advanced settings) Display Setting/selection Electronic gas flow control, type 1 = ------- type A (ex works) 0 = ------- type B Program settings for relative programs 0 = ------- Combined setting of relative programs possible (ex works). 1 = ------- Individual setting of relative programs possible (ex works).
Functional characteristics Special parameters (advanced settings) 5.10.1.5 Special cycle in the operating modes special latched and non-latched (P5) With the special sequence activated, the start of the welding process changes as follows: Sequence for special non-latched mode/special latched mode: • Start program "P "...
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". •...
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". •...
Functional characteristics Special parameters (advanced settings) 5.10.1.11 JOB list switching (P12) 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 skip- ped.
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, up to 30 JOBs (welding tasks) divided into three blocks can be called up with ac- cessory components.
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).
Functional characteristics Special parameters (advanced settings) 5.10.1.27 Selection option – Program sequence with welding power rotary knob (P30) Function not active • The rotary knob is locked, use the welding parameters push-button to select the welding parameters. Function active • Rotary knob can be used to select the welding parameters.
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 dea- ler.
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Rectifying faults Error messages (power source) Category Error Possible cause Remedy Low coolant le- Flow rate too low (< = 0.7 l/min) Check coolant flow, clean wa- / (< = 0.18 gal/min) [1] [3] ter block, remove kinks in hose package, adjust flow threshold Coolant volume too low Fill coolant...
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Rectifying faults Error messages (power source) Category Error Possible cause Remedy No wire feeder After switching on the automa- Check or connect control ted system, no wire feeder was cables of wire feeders; check detected the identification number of the automated wire feeder (for 1DV: number 1, for 2DV: each a wire feeder with number 1 and a wire feeder with number...
Rectifying faults Warnings Warnings Depending on the display options of the machine display, a warning message is displayed as follows: Display type - machine control Display Graphic display two 7-segment displays one 7-segment display The cause of the warning is indicated by a corresponding warning number (see table). •...
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.
Appendix JOB-List Appendix JOB-List JOB no. Processes Material Diameter [mm] GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 Standard GMAW / pulse...
Appendix Searching for a dealer Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-5TLPXQ-EW501 29.01.2021...
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