Subscribe to Our Youtube Channel
Related Manuals for EWM Drive 4X D200 Basic S
Summary of Contents for EWM Drive 4X D200 Basic S
- Page 1 Operating instructions Wire feed unit Drive 4 Basic S Drive 4X Steel Synergic S Drive 4X Steel puls S 099-005593-EW501 Observe additional system documents! 10.01.2022...
- Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted.
-
Page 3: Table Of Contents
Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................5 Notes on using these operating instructions ................5 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ....................10 3 Intended use .......................... - Page 4 Contents Notes on using these operating instructions 7 Rectifying faults ..........................39 Error messages (power source) ................... 39 Warnings ..........................42 Checklist for rectifying faults ....................44 Vent coolant circuit ....................... 46 8 Technical data ..........................47 Drive 4 Basic S, -Steel Synergic S, -Steel puls S ..............47 9 Accessories ..........................
-
Page 5: For Your Safety
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. •... -
Page 6: Explanation Of Icons
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 Numerical value –... -
Page 7: 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 8 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 9 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
-
Page 10: Transport And Installation
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. - Page 11 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.
-
Page 12: 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 stand- ards applicable for use in industry and trade. It may only be used for the welding proce- dures indicated at the rating plate. -
Page 13: Documents Which Also Apply
3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the decla- ration. -
Page 14: Part Of The Complete Documentation
Intended use Documents which also apply 3.3.5 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. -
Page 15: Machine Description - Quick Overview
Machine description – quick overview Front view / side view from the right Machine description – quick overview Front view / side view from the right Figure 4-1 099-005593-EW501 10.01.2022... - Page 16 Machine description – quick overview Front view / side view from the right Item Symbol Description Carrying handle Protective cap, welding machine control > see 5.2.3 chapter Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Turning mandrel support The wire feeder is placed onto the power source turning mandrel using this support to enable horizontal pivoting of the machine.
-
Page 17: Rear View / Side View From Left
Machine description – quick overview Rear view / side view from left Rear view / side view from left Figure 4-2 099-005593-EW501 10.01.2022... - Page 18 Machine description – quick overview Rear view / side view from left Item Symbol Description Power source welding current connector plug Welding current connection between power source and wire feeder Connection thread - G¼" Shielding gas connection (inlet) 7-pole connection socket (digital) •...
-
Page 19: Design And Function
Design and function Transport and installation Design and function WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •... -
Page 20: Welding Torch Cooling System
All information relates to the total hose package length of the complete welding system and presents exemplary configurations (of components of the EWM product portfolio with standard lengths). A straight kink-free installation is to be ensured, taking into account the max. delivery height. -
Page 21: Notes On The Installation Of Welding Current Leads
Design and function Transport and installation 5.1.3 Notes on the installation of welding current leads • Incorrectly installed welding current leads can cause faults in the arc (flickering). • Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel. -
Page 22: Stray Welding Currents
Design and function Intermediate hose package connection 5.1.4 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and electronic devices and cause overheating of components, leading to fire. •... - Page 23 Design and function Intermediate hose package connection Figure 5-5 Item Symbol Description Power source Intermediate hose package Power source welding current connector plug Welding current connection between power source and wire feeder Connection thread - G¼" Shielding gas connection (inlet) Quick connect coupling (red) coolant return 7-pole connection socket (digital)
-
Page 24: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)
Design and function Intermediate hose package connection 5.2.1 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 25: Gas Test
Design and function Intermediate hose package connection 5.2.2.1 Gas test The operating elements are installed under the protective cap of wire feed mechanism. Figure 5-7 5.2.2.2 Purge hose package The operating elements are installed under the protective cap of wire feed mechanism. 300s Figure 5-8 5.2.3... -
Page 26: Mig/Mag Welding
Design and function MIG/MAG welding MIG/MAG welding 5.3.1 Assemble the wire guide The Euro torch connector is factory-fitted with a guide tube for welding torches with steel liner. Conver- sion is necessary if a welding torch with a steel liner is used! •... -
Page 27: Welding Torch Connection
Design and function MIG/MAG welding 5.3.2 Welding torch connection Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coo- lant circuit is interrupted and equipment damage can occur. •... -
Page 28: 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 29: Changing The Wire Feed Rollers
Design and function MIG/MAG welding Figure 5-14 Observe the unwinding direction of the wire spool. 5.3.3.2 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. - Page 30 Design and function MIG/MAG welding • Rotate the tommy by 90° clockwise or anti-clockwise (tommy locks into place). • Fold the closure brackets outwards by 90°. • Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip up- wards).
- Page 31 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 32: Inching The Wire Electrode
Design and function MIG/MAG welding 5.3.3.3 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 in- jury including injuries to the face and eyes! •... -
Page 33: Spool Brake Setting
Design and function MIG/MAG welding • The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll ten- sioner setting nuts depending on the welding consumable used. A table with the setting values can be found on a sticker near the wire drive. -
Page 34: Mig/Mag Special-Torches
Design and function MMA welding or gouging 5.3.5 MIG/MAG special-torches 5.3.5.1 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 35: Welding Task Selection
Design and function Remote control Item Symbol Description Intermediate hose package Power source Workpiece • Insert the electrode holder or gouge plug into the welding current connection socket (wire feeder) and lock in place by turning to the right. The welding current polarity is changed by reconnecting the welding power plug (intermediate hose package) at the power source. -
Page 36: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed. -
Page 37: Maintenance Work, Intervals
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-005593-EW501 10.01.2022... -
Page 38: Disposing Of Equipment
Information on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further information on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html. -
Page 39: Rectifying Faults
Rectifying faults Error messages (power source) 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. - Page 40 Rectifying faults Error messages (power source) Error (category) Possible cause Remedy Low coolant level low flow rate Fill coolant. Check coolant flow - remove kinks in hose package. [1] [3] Adjust flow threshold. Clean water block. Pump does not turn Turn the pump shaft.
- Page 41 Rectifying faults Error messages (power source) Error (category) Possible cause Remedy 33 Error UIST Voltage recording faulty Eliminate short circuit in welding cir- cuit. remove external sensor voltage. Request service. 34 Electronics error A/D-channel error Switch the machine off and on again. Request service.
-
Page 42: Warnings
Rectifying faults Warnings Error (category) Possible cause Remedy 56 Mains phase failure One phase of the mains voltage Check mains connection, mains plug has failed. and mains fuses. Slave tacho error Wire feeder fault (slave drive). Check connectors, cables, connec- tions. - Page 43 Rectifying faults Warnings Warning Possible cause / remedy 8 Welding circuit The inductance of the welding circuit is too high for the selected welding task. 9 WF configuration Check WF configuration. 10 Partial inverter One of several partial inverters is not supplying welding current. 11 Excess temperature of the coo- Check temperature and switching thresholds.
-
Page 44: Checklist For Rectifying Faults
Rectifying faults Checklist for rectifying faults Warning Possible cause / remedy 38 Incomplete component informa- Check XNET component management. tion 39 Mains half-wave failure Check supply voltage. 40 Weak power grid Check supply voltage. 41 Cooling unit not recognised Check the cooling unit connection. 47 Battery (Bluetooth remote con- Battery level is low (replace battery) trol) - Page 45 Rectifying faults Checklist for rectifying faults Coolant error/no coolant flowing Insufficient coolant flow Check coolant level and refill if necessary Air in the coolant circuit Vent coolant circuit > see 7.4 chapter Wire feed problems Wire feed roll holder is worn (wire feed rolls must be firmly seated on their holders and must not have any play) ...
-
Page 46: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit Figure 7-1 • Switch off the machine and fill the coolant tank to the maximum level. • Unlock the quick-connect coupling with a suitable tool (connection open). 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 •... -
Page 47: Technical Data
Technical data Drive 4 Basic S, -Steel Synergic S, -Steel puls S Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Drive 4 Basic S, -Steel Synergic S, -Steel puls S Supply voltage (from the welding machine) 42 VAC Duty cycle DC at 40°... -
Page 48: Accessories
Accessories General accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. DM 842 Ar/CO2 230bar 30l D Pressure regulator with manometer 394-002910-00030 AK300 Wire spool adapter K300 094-001803-00001 HOSE BRIDGE UNI... -
Page 49: Options
Accessories Options Options Type Designation Item no. ON GK D01 Metal runners 092-003030-00000 ON WAK D01 Wheel assembly kit 092-002844-00000 ON PS EXT D01 Retrofit set: Extension turning mandrel, for holding a 092-002871-00000 wire feeder with wheel kit ON WAK D01 ON RFAK D01 Rubber feet 092-002845-00000... -
Page 50: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable parts Performance specifications and guarantee only in connection with original spare and replacement parts! 10.1 Wire feed rollers 10.1.1 Wire feed rollers for steel wire Type Designation Item no. FE 4R 0.6 MM/0.023 INCH Drive roll set, 37 mm, 4 rolls, V-groove for steel, 092-002770-00006 LIGHT PINK... -
Page 51: 10.1.3 Wire Feed Rollers For Cored Wire
Replaceable parts Wire feed rollers 10.1.3 Wire feed rollers for cored wire Type Designation Item no. FUEL 4R 0.8 MM/0.03 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00008 WHITE/ORANGE flux cored wire FUEL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, 4 rolls, V-groove/knurled for 092-002848-00010 BLUE/ORANGE... -
Page 52: Appendix
Appendix Searching for a dealer Appendix 11.1 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-005593-EW501 10.01.2022...
Need help?
Do you have a question about the Drive 4X D200 Basic S and is the answer not in the manual?
Questions and answers