EWM alpha Q 330 Progress puls HP MM TKM Operating Instructions Manual
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EWM alpha Q 330 Progress puls HP MM TKM Operating Instructions Manual

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Operating instructions
Welding machine
EN
alpha Q 330 Progress puls HP MM TKM
099-005402-EW501
Observe additional system documents!
24.11.2016

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Summary of Contents for EWM alpha Q 330 Progress puls HP MM TKM

  • Page 1 Operating instructions Welding machine alpha Q 330 Progress puls HP MM TKM 099-005402-EW501 Observe additional system documents! 24.11.2016...
  • 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.

  • Page 3: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 Part of the complete documentation ....................8 Safety instructions ..........................
  • Page 4 Contents Notes on the use of these operating instructions 5.3.6 MIG/MAG operating point ..................... 46 5.3.6.1 Operating point setting via welding current, material thickness or wire feed speed ..................... 46 5.3.6.2 Arc length correction setting ................47 5.3.6.3 Accessory components for operating point setting ........47 5.3.6.4 coldArc / coldArc puls ..................
  • Page 5 Wire feed rollers for aluminium wire ................120 10.1.3 Wire feed rollers for cored wire .................. 120 10.1.4 Wire guide ........................120 11 Appendix A ............................121 11.1 JOB-List ............................. 121 12 Appendix B ............................128 12.1 Overview of EWM branches ...................... 128 099-005402-EW501 24.11.2016...

  • Page 6: 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 7: 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 Numerical value – adjustable Correct Menu entry Signal light lights up in green...

  • Page 8: 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 9: Safety Instructions

    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! •...
  • Page 10 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.
  • Page 11 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! •...
  • Page 12 For your safety Safety instructions CAUTION 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 13: Transport And Installation

    For your safety Transport and installation Transport and installation WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! • Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air! •...

  • Page 14: Intended Use

    Intended use Applications Intended use WARNING Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and standards applicable for use in industry and trade. It may only be used for the welding procedures indicated at the rating plate.

  • Page 15: Documents Which Also Apply

    In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product.

  • Page 16: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 099-005402-EW501 24.11.2016...
  • Page 17 Machine description – quick overview Front view Item Symbol Description Transport bar Machine control > see 4.4 chapter Main switch, machine on/off 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Connection socket 7-pole (digital) For connecting digital accessory components (remote control, etc.).

  • Page 18: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-005402-EW501 24.11.2016...
  • Page 19 Machine description – quick overview Rear view Item Symbol Description Slide latch, lock for the protective cap Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, additional stickers with information on the replacement parts and JOB lists will be located on the inside.

  • Page 20: Inside View

    Machine description – quick overview Inside view Inside view Figure 4-3 099-005402-EW501 24.11.2016...
  • Page 21 Machine description – quick overview Inside view Item Symbol Description Welding torch function changeover switch (special welding torch required) Changing over programs or JOBs Infinite adjustment of welding performance. Wire spool holder Wire feed unit 099-005402-EW501 24.11.2016...

  • Page 22: 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 JOB- Welding task push-button (JOB) LIST Select the welding task from the welding task list (JOB-LIST). The list can be found inside the protective cap on the wire feeder and in the appendix to these operating instructions.
  • Page 23 Machine description – quick overview Machine control – Operating elements Item Symbol Description Select operating mode button --------- Non-latched -------- Latched --------- Signal light lights up in green: Special non-latched ---- Signal light lights up in red: MIG spot welding -------- Special latched Welding type push-button -------- Standard arc welding...

  • Page 24: Functional Sequence

    Machine description – quick overview Machine control – Operating elements 4.4.1 Functional sequence Figure 4-5 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used. Signal light, gas pre-flow time Setting range 0.0 s to 20.0 s Signal light, start program (P...

  • Page 25: Design And Function

    Design and function Transport and installation Design and function 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 26: Machine Cooling

    Design and function Transport and installation 5.1.2 Machine cooling Insufficient ventilation results in a reduction in performance and equipment damage. • Observe the ambient conditions! • Keep the cooling air inlet and outlet clear! • Observe the minimum distance of 0.5 m from obstacles! 5.1.3 Workpiece lead, general CAUTION...

  • Page 27: Notes On The Installation Of Welding Current Leads

    Design and function Transport and installation 5.1.5 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 28: Stray Welding Currents

    Design and function Transport and installation 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. Figure 5-4 5.1.5.1 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and...

  • Page 29: Mains Connection

    Design and function Transport and installation 5.1.6 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only operate machine using a socket that has correctly fitted protective earth. • The mains voltage indicated on the rating plate must match the supply voltage.

  • Page 30: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function Transport and installation 5.1.7 Shielding gas supply (shielding gas cylinder for welding machine) WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! •...

  • Page 31: Shielding Gas Hose Connection

    Design and function Transport and installation 5.1.7.2 Shielding gas hose connection Figure 5-8 Item Symbol Description Connecting nipple G¼, shielding gas connection • Connect crown nut of the shielding gas line to the G¼“ connecting nipple. 099-005402-EW501 24.11.2016...

  • Page 32: Shielding Gas Volume Settings

    Design and function Transport and installation 5.1.8 Shielding gas volume settings CAUTION Electric shocks! When setting the shielding gas quantity, high voltage ignition pulses or open circuit voltage are applied at the welding torch; these can lead to electric shocks and burning on contact.

  • Page 33: Welding Data Display

    Design and function Welding data display 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 34: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.3.1 Welding torch connection On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a steel liner. Conversion is necessary if a welding torch with a liner is used! •...
  • Page 35 Design and function MIG/MAG welding Figure 5-12 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 •...

  • Page 36: Connection For Workpiece Lead

    Design and function MIG/MAG welding 5.3.2 Connection for workpiece lead Figure 5-13 Item Symbol Description Workpiece "-" welding current connection socket • ---------- MIG/MAG welding: Workpiece connection • Insert the plug on the workpiece lead into the "-" welding current connection socket and lock. 099-005402-EW501 24.11.2016...

  • Page 37: Wire Feed

    Design and function MIG/MAG welding 5.3.3 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 38: Inserting The Wire Spool

    Design and function MIG/MAG welding 5.3.3.2 Inserting the wire spool CAUTION Risk of injury due to incorrectly secured wire spool. If the wire spool is not secured properly, it may come loose from the wire spool support and fall to the ground, causing damage to the machine and injuries. •...

  • Page 39: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.3.3.3 Changing the wire feed rollers Figure 5-15 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 40 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 41: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.3.3.4 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 42: 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 5.3.1 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 43: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.3.4 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 44: Choke Effect / Dynamics

    Design and function MIG/MAG welding 5.3.5.2 Choke effect / dynamics Setting range: Arc hard and narrow, deeper fusion penetration. -40: Arc soft and wide. ENTER EXIT Figure 5-20 5.3.5.3 Burn-back ENTER EXIT Figure 5-21 Display Setting/selection menu burn back Set burn back 099-005402-EW501 24.11.2016...

  • Page 45: Superpuls

    (PB). This function is e.g. used for thin sheet welding to reduce the heat input in a controlled manner or for positional welding without the need for weaving. The combination of superPuls and other EWM welding processes offers a multitude of possibilities. For example, to enable the welding of vertical-up welds without the "Christmas tree" technique, when selecting program 1 >...

  • Page 46: Mig/Mag Operating Point

    Design and function MIG/MAG welding 5.3.6 MIG/MAG operating point The operating point (welding power) is specified using the MIG/MAG one-knob operation principle, i.e. the user can specify either the welding current, the wire feed speed or the material thickness to define the operating point.

  • Page 47: Arc Length Correction Setting

    Design and function MIG/MAG welding 5.3.6.2 Arc length correction setting When required, the arc length (welding voltage) can be adjusted for the welding task in hand by +/– 9.9 V. Figure 5-24 5.3.6.3 Accessory components for operating point setting The operating point can be set at various accessory components as well, such as remote control, special welding torches or robot and industrial bus interfaces (optional interface for automated welding required, not available for all machines of this series).

  • Page 48: Coldarc / Coldarc Puls

    Design and function MIG/MAG welding 5.3.6.4 coldArc / coldArc puls Heat-reduced, low-spatter short arc for high dimensional stability welding and brazing, plus root welding with excellent gap bridging capabilities. Figure 5-25 After selecting the coldArc process > see 5.3.5 chapter the following properties are available: •...

  • Page 49: Forcearc / Forcearc Puls

    Design and function MIG/MAG welding 5.3.6.5 forceArc / forceArc puls Low-heat, directionally stable and powerful high-performance arc with deep fusion penetration for the upper power range Unalloyed, low-alloy and high-alloy steels as well as high-tensile fine-grained steels. Figure 5-26 • Smaller included angle due to deep penetration and directionally stable arc •...

  • Page 50: Rootarc/Rootarc Puls

    Design and function MIG/MAG welding 5.3.6.6 rootArc/rootArc puls Short arc with perfect weld modelling capabilities for effortless gap bridging, especially for positional welding Figure 5-27 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion •...

  • Page 51: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 5.3.7 MIG/MAG functional sequences / operating modes 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). 5.3.7.1 Explanation of signs and functions Symbol Meaning Press torch trigger...
  • Page 52 Design and function MIG/MAG welding Non-latched mode Figure 5-29 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 53 Design and function MIG/MAG welding Non-latched operation with superpulse Figure 5-30 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 54 Design and function MIG/MAG welding Special, non-latched 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 is flowing (start program P for the time t START...
  • Page 55 Design and function MIG/MAG welding Spot welding Figure 5-32 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 56 Design and function MIG/MAG welding Special, non-latched with superpulse 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 57 Design and function MIG/MAG welding Latched mode Figure 5-34 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 58 Design and function MIG/MAG welding Latched mode 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 flows. •...
  • Page 59 Design and function MIG/MAG welding Latched with changing welding method (process switching) To activate or set the function > see 5.3.14 chapter. Figure 5-36 1st cycle: • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed"...
  • Page 60 Design and function MIG/MAG welding Latched special 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 is flowing (start program P START Step 2...
  • Page 61 Design and function MIG/MAG welding Special latched with changing welding method by tapping (process switching) To activate or set the function > see 5.3.14 chapter. Figure 5-38 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) •...
  • Page 62 Design and function MIG/MAG welding Special latched with changing welding method (process switching) To activate or set the function > see 5.3.14 chapter. Figure 5-39 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) •...
  • Page 63 Design and function MIG/MAG welding Special, latched with superpulse Figure 5-40 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 64: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.3.8 MIG/MAG program sequence ("Program steps" mode) Certain materials, such as aluminium, require special functions in order to be able to weld them safely and at high quality. The latched special operating mode is used here with the following programs: •...

  • Page 65: Mig/Mag Overview Of Parameters

    Design and function MIG/MAG welding 5.3.8.2 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 66: Example, Tack Welding (Non-Latched)

    Design and function MIG/MAG welding 5.3.8.3 Example, tack welding (non-latched) Figure 5-44 Basic parameters Parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 67: Example, Aluminium Welding (Latched Special)

    Design and function MIG/MAG welding 5.3.8.5 Example, aluminium welding (latched special) Figure 5-46 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 68: Example, Visible Seams (Latched Super Pulse)

    Design and function MIG/MAG welding 5.3.8.6 Example, visible seams (latched super pulse) 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 69: Conventional Mig/Mag Welding (Gmaw Non Synergic)

    Design and function MIG/MAG welding 5.3.9 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 70: 5.3.10 Main Program A Mode

    Design and function MIG/MAG welding 5.3.10 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 71 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 72: Selecting Parameters (Program A)

    Design and function MIG/MAG welding 5.3.10.1 Selecting parameters (program A) Changes to the welding parameters can only be made when the key switch is in position "1". Figure 5-53 Select program number. 5.3.11 MIG/MAG automatic cut-out The welding machine ends the ignition process or the welding process with an •...

  • Page 73: 5.3.12 Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.3.12 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 74: 5.3.13.2 Switching Between Push/Pull And Intermediate Drive

    Design and function MIG/MAG welding 5.3.13.2 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.

  • Page 75: Expert Menu (Mig/Mag)

    Design and function MIG/MAG welding 5.3.14 Expert menu (MIG/MAG) The expert menu includes functions and parameters which are either not set on the machine control, or which do not require regular setting. 5.3.14.1 Selection ENTER (Enter the menu) • Keep the "welding parameters" push-button pressed for 3 s. NAVIGATION (Navigate the menu) •...
  • Page 76 Design and function MIG/MAG welding Display Setting/selection Correct wire burn-back If too high a value is set, a large ball will form at the tip of the wire electrode (bad re- ignition) or the wire electrode sticks to the contact tip. If too low a value is set, the wire electrode sticks to the weld pool.

  • Page 77: Tig Welding

    Design and function TIG welding TIG welding 5.4.1 Welding torch and workpiece line connection Figure 5-56 Item Symbol Description Welding torch Welding torch hose package "-" welding current connection socket • Welding current connection for welding torch TIG welding: Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Workpiece Connection socket, "+"...

  • Page 78: Welding Task Selection

    Design and function TIG welding 5.4.2 Welding task selection EXIT Figure 5-57 Item Symbol Description JOB- Welding task push-button (JOB) LIST Select the welding task from the welding task list (JOB-LIST). The list can be found inside the protective cap on the wire feeder and in the appendix to these operating instructions.

  • Page 79: Tig Arc Ignition

    Design and function TIG welding 5.4.3 TIG arc ignition 5.4.3.1 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 80 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 81 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 82: Tig Automatic Cut-Out

    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 83: Tig Program Sequence ("Program Steps" Mode)

    Design and function TIG welding 5.4.5 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 84: 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 85: Welding Task Selection

    Design and function MMA welding 5.5.2 Welding task selection You can only change the JOB number when no welding current is flowing. EXIT Figure 5-66 Item Symbol Description JOB- Welding task push-button (JOB) LIST Select the welding task from the welding task list (JOB-LIST). The list can be found inside the protective cap on the wire feeder and in the appendix to these operating instructions.

  • Page 86: Arcforce

    Design and function MMA welding 5.5.2.2 Arcforce Figure 5-68 Setting: • Negative values: rutile electrode types • Values at zero: basic electrode types • Positive values: cellulose electrode types 5.5.2.3 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) =...

  • Page 87: Parameter Overview

    Design and function MMA welding 5.5.3 Parameter overview Figure 5-71 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. 099-005402-EW501 24.11.2016...

  • Page 88: 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 89: 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 90: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.9.2 Remote control connection socket, 19-pole Figure 5-72 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 91: Rint X12 Robot Interface

    Design and function PC interface 5.9.3 RINT X12 robot interface The standard digital interface for mechanised applications
 Functions and signals: • Digital inputs: start/stop, operating modes, JOB and program selection, inching, gas test • Analogue inputs: control voltages, e.g. for welding performance, welding current, etc. •...

  • Page 92: Special Parameters (Advanced Settings)

    Design and function Special parameters (advanced settings) 5.11 Special parameters (advanced settings) Special parameters (P1 to Pn) are applied for customer-specific configuration of machine functions. This allows the user maximum flexibility in optimising their requirements. These settings are not configured directly on the machine control since a regular setting of the parameters is generally not required.
  • Page 93 Design and function Special parameters (advanced settings) Display Setting/selection Program limitation Programs 1 to max. 15 Ex works: 15 Special cycle in the special latched and non-latched operating modes 0 = -------- normal (previous) non-latched/latched (Ex works) 1 = -------- WF3 cycle for non-latched/latched Correction operation, threshold value setting 0 = -------- correction operation switched off (Ex works) 1 = -------- correction operation on...

  • Page 94: 5.11.1.1 Reset To Factory Settings

    Design and function Special parameters (advanced settings) Display Setting/selection Predefined pulse arc welding process in the PA program 0 = ------- Predefined pulse arc welding process in the PA program is disabled. 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).

  • Page 95: Special Parameters In Detail

    Design and function Special parameters (advanced settings) 5.11.1.2 Special parameters in detail Ramp time for wire inching (P1) The wire inching starts with a speed 1.0 m/min for 2 secs. It is subsequently increased to a ramp function to 6.0 m/min. The ramp time can be set between two ranges. During wire inching, the speed can be changed by means of the welding parameter setting rotary dial.
  • Page 96 Design and function Special parameters (advanced settings) 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 97 Design and function Special parameters (advanced settings) Setting the correction range: • Activate the “correction operation” special parameter (P7=1) and save. > see 5.12.1 chapter • Key switch to position "1". • Set the correction range as follows: EXIT Figure 5-76 •...
  • Page 98 Design and function Special parameters (advanced settings) 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 99 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 100 Design and function Special parameters (advanced settings) "Single or dual operation" (P10) setting If the system is fitted with two wire feeds, no further accessory components may be operated on the 7-pole connection socket (digital)! This relates to digital remote controls, robot interfaces, documentation interfaces, welding torches with digital control lead connection, etc.
  • Page 101 Design and function Special parameters (advanced settings) Copying JOBs, "Copy to" function The possible target range is between 129 - 169. • First configure special parameter P12 to P12 = 2 or P12 = 1! Figure 5-79 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 102 Design and function Special parameters (advanced settings) 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, a total of 27 JOBs (welding tasks) divided into three blocks can be called up using accessory components.

  • Page 103: Machine Configuration Menu

    Design and function Machine configuration menu Mean value display for superPuls (P19) Function active (P19 = 1) • For superPuls, the performance mean value from program A (P ) and program B (P ) is shown on the display (ex factory). Function inactive (P19 = 0) •...
  • Page 104 Design and function Machine configuration menu ENTER EXIT NAVIGATION Figure 5-80 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-controlled power-saving mode >...

  • Page 105: 5.12.2 Aligning The Cable Resistance

    Design and function Machine configuration menu 5.12.2 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 intermediate hose package and a 3 m water-cooled welding torch.
  • Page 106 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 107: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal General DANGER Incorrect maintenance and testing! The machine may be cleaned, repaired and tested by skilled and qualified personnel only. A qualified person is one who, due to their training, knowledge and experience, can detect any hazards and possible consequential damage when checking the machine, and can take the necessary safety measures.

  • Page 108: Maintenance Work, Intervals

    Maintenance, care and disposal Maintenance work, intervals Maintenance work, intervals Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine.

  • Page 109: Annual Test (Inspection And Testing During Operation)

    In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives on the Declaration of Conformity on your machine).

  • Page 110: 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 111: Error Messages (Power Source)

    Rectifying faults Error messages (power source) Error messages (power source) 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 112 Rectifying faults Error messages (power source) Legend for categories (reset 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 CarExpert / Progress (M3.11)

  • Page 113: Resetting Jobs (Welding Tasks) To The Factory Settings

    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. 7.3.1 Resetting a single JOB EXIT Figure 7-1 Display Setting/selection RESET to factory settings...

  • Page 114: Resetting All Jobs

    Rectifying faults General operating problems 7.3.2 Resetting all JOBs JOBs 1–128 and 170–256 will be reset. Custom JOBs 129–169 are maintained. EXIT Figure 7-2 Display Setting/selection RESET to factory settings The RESET will be done after pressing the button. The menu will be ended when no changes are done after 3 sec. General operating problems 7.4.1 Automation interface...

  • Page 115: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit 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 7-3 099-005402-EW501...

  • Page 116: Technical Data

    Technical data alpha Q 330 Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! alpha Q 330 MIG/MAG Setting range for welding current 5 A–330 A Setting range for welding voltage 14.3 V–30.5 V 20.2 V–33.2 V 10.2 V–23.2 V Duty cycle at 40 °C / 40%...

  • Page 117: 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. Cool71 U42 Air cooling unit, heavy-duty pump and enhanced 090-008201-00502 cooling cool71 U43 Cooling unit with centrif.

  • Page 118: Remote Control/Connecting And Extension Cable

    Accessories Remote control/connecting and extension cable Remote control/connecting and extension cable 9.4.1 7-pole connection Type Designation Item no. R40 7POL Remote control, 10 programs 090-008088-00000 R50 7POL Remote control, all welding machine functions can 090-008776-00000 be set directly at the workplace FRV 7POL 0.5 m Extension/connecting cable 092-000201-00004...

  • Page 119: Replaceable Parts

    Replaceable parts Wire feed rollers Replaceable 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 120: 10.1.2 Wire Feed Rollers For Aluminium Wire

    Replaceable parts Wire feed rollers 10.1.2 Wire feed rollers for aluminium wire Type Designation Item no. AL 4R 0.8 MM/0.03 INCH Drive roll set, 37 mm, for aluminium 092-002771-00008 WHITE AL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, for aluminium 092-002771-00010 BLUE AL 4R 1.2 MM/0.045 INCH...

  • Page 121: 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 G3Si1/G4Si1 100% CO2 Standard GMAW/puls G3Si1/G4Si1 100% CO2 Standard GMAW/puls G3Si1/G4Si1 Ar-82/CO2-18 (M21) Standard GMAW/puls...
  • Page 122 Appendix A JOB-List JOB no. Processes Material Diameter [mm] 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 Ar-100 (I1) Ar-100 (I1) coldArc brazing CuSi coldArc brazing...
  • Page 123 Appendix A JOB-List JOB no. Processes Material Diameter [mm] 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) Brazing CuAl Ar-97,5/CO2-2,5 (M12)
  • Page 124 Appendix A JOB-List JOB no. Processes Material Diameter [mm] 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 CO2-100 (C1)
  • Page 125 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Surfacing G3Si1/G4Si1 Ar-82/CO2-18 (M21) Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Surfacing Ar-82/CO2-18 (M21) G3Si1/G4Si1 Surfacing G3Si1/G4Si1 Ar-82/CO2-18 (M21) Ar-100 (I1) 220* coldArc - St/Al ZnAl coldArc - St/Al Ar-100 (I1) 221* ZnAl coldArc - St/Al Ar-100 (I1) 224* AlSi...
  • Page 126 Appendix A JOB-List JOB no. Processes Material Diameter [mm] Standard GMAW/puls NiCr 617 Ar-70/He-30 (I3) 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-70/He-30 (I3) Standard GMAW/puls NiCr 625 Ar-67,95/He-30/H2-2 / CO2-0,05 Standard GMAW/puls NiCr 625 Ar-67,95/He-30/H2-2 /...
  • Page 127 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 128: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005402-EW501 24.11.2016...

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