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Operating instructions Control T5.00 - AC/DC Comfort 3.0 099-00T500-EW501 Observe additional system documents! 2.9.2022...
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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 f orm 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 Saf ety instructions ....................8 Transport and installation ..................11 3 Intended use ........................13 Use and operation solely with the following machines ..........13 Software version ....................13 Documents which also apply ...................14...
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Contents Notes on using these operating instructions 5.2.6 TIG activArc welding ................41 5.2.7 TIG antistick....................41 5.2.8 Pulse welding..................42 5.2.9 Average value pulse welding ..............42 5.2.9.1 Thermal pulsing .................43 5.2.9.2 Automated pulses...............43 5.2.9.3 AC special.................44 5.2.9.4 Pulsing in an upslope/downslope ..........44 5.2.10 Welding torch (operating variants) ..............45 5.2.10.1 Welding torch mode ..............45...
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Contents Notes on using these operating instructions Searching for a dealer....................81 099-00T500-EW501 2.9.2022...
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. • Saf ety 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 Activate and release / Tap / Tip user must observe. Switch off machine Release Switch on machine Press and hold Incorrect / Invalid Switch Correct / Valid Turn...
For your safety Saf ety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Caref ully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •...
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For your safety Saf ety 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 Saf ety 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! •...
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.
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.
Intended use Documents which also apply 3.3.6 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 three sections (A, B, C) to ensure maximum clarity. The setting range 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 System push-button • ----------- Quick access to various device configuration parameters. For the complete parameter list, see the machine configuration menu > see 5.11 chapter •...
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Machine control – Operating elements Overview of control sections Item Symbol Description Push-button for operating modes > see 5.2.5 chapter ---------- Latched ------- Non-latched - Spot welding procedure spotArc Spot welding procedure spotmatic Pulsing push-button > see 5.2.8 chapter ------- Average value pulsing ----- Thermal pulsing --- Automated pulsing - AC special...
Machine control – Operating elements Overview of control sections 4.1.2 Control section B Figure 4-3 Item Symbol Description TIG ignition type signal light Signal light on: Lift arc ignition active/HF start off. You can switch the ignition type in the Expert menu (TIG) >...
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Machine control – Operating elements Overview of control sections Item Symbol Description Signal light for status display Af ter each completed welding process, the last values used for welding current and vol- tage are shown in the displays and the signal light is on. Access control active signal light Signal light is on when access control is active on the machine con- trol >...
Machine control – Operating elements Overview of control sections 4.1.3 Control section C Figure 4-4 Item Symbol Description Signal light for main current /pulse current Signal light for up-slope time Signal light for start current Signal light for electrode diameter Gas pre-flow time signal light Signal light for ignition optimisation (TIG) Signal light for welding task (JOB)
Machine control – Operating elements Machine display Item Symbol Description Signal light for secondary current Machine display The f ollowing welding parameters can be displayed before (nominal values), during (actual values) or af - ter welding (hold values). The display of the hold values is indicated by the signal light Parameter Bef ore welding During welding...
Machine control – Operating elements Operating the machine control 4.3.4 Setting advanced welding parameters (Expert menu) The Expert menu contains functions and parameters that cannot be set directly on the machine control or f or which regular settings are not required. The number and display of these parameters depend on the previously selected welding procedure or functions.
Functional characteristics TIG welding Functional characteristics TIG welding 5.1.1 Setting the shielding gas volume (gas test)/rinse hose package • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. •...
Functional characteristics TIG welding 5.1.2 Welding task selection By setting the tungsten electrode diameter , the TIG ignition behaviour (ignition energy), machine f unctions and minimum current limit are preset optimally. Smaller electrode diameters require less ignition energy than larger electrode diameters. If necessary, the ignition energy >...
Functional characteristics TIG welding 5.1.4 Manual ignition setting When the special ignition is selected, the dependency of the minimum current limits on the electrode dia- meter is disabled. The ignition energy can now be set independently with the parameters ignition current and ignition time .
Functional characteristics TIG welding 5.1.4.1 Recurring welding tasks (JOB 1-100) The user has 100 additional memory locations at their disposal to save recurring or different welding tasks on a permanent basis. To do so, simply select the required memory location (JOB 1-100) and set the welding task as described previously.
Functional characteristics Welding programs Welding programs The welding programs function is factory set to disabled and must be activated for use with the parame- in the machine configuration menu > see 5.11 chapter. In each selected welding task (JOB), > see 5.1.2 chapter, 16 programs can be set, saved and called up. In program “0”...
Functional characteristics Welding programs 5.2.3 AC welding The welding of aluminium and aluminium alloys is made possible by the periodic change of polarity on the tungsten electrode. The negative pole (negative half-wave) of the tungsten electrode determines the penetration characteris- tics and has a lower electrode load compared to the positive half-wave.
Functional characteristics Welding programs 5.2.3.2 Tungsten balling function The tungsten balling function achieves an optimal balled end enabling the best ignition and welding re- sults f or AC welding. Optimal tungsten balling requires a sharpened electrode (about 15–25 °) and the set electrode diameter on the machine control.
Functional characteristics Welding programs 5.2.3.3 AC balance (optimise cleaning effect and penetration characteristics) It is important to choose the right time relationship (balance) between the positive phase (cleaning effect, balled end size) and the negative phase (penetration depth). This may differ from the factory setting de- pending on the material and task.
Functional characteristics Welding programs 5.2.3.5 Automatic AC frequency Activation takes place in the functional sequence using the parameter frequency . By turning to the left, the parameter value is reduced until the parameter (AC frequency automatic) is shown in the display. The signal light comes on when the function is enabled.
Functional characteristics Welding programs 5.2.3.6 AC commutation optimisation With AC welding, a periodic change between positive and negative half-wave takes place. This pole change is called commutation. External influences such as low-alloy aluminium materials (such as Al 99.5) or gases that are difficult to ionize (Ar/He mixtures) may compromise the commutation and lead to lower arc stability and higher noise levels.
Functional characteristics Welding programs 5.2.4.2 Liftarc Figure 5-15 The arc is ignited on contact with the workpiece: a) Caref ully 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). b) Incline the torch over the torch gas nozzle to produce a gap of approx.
Functional characteristics Welding programs 5.2.5 Operating modes (functional sequences) 5.2.5.1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 Current Time Gas pre-f low Start current Start time Up-slope time Spot time Main current (minimum to maximum current) Secondary current AMP% Pulse time...
Functional characteristics Welding programs 5.2.5.2 Non-latched mode Sequence Figure 5-16 cycle: • Press and hold torch trigger 1. • The gas pre-flow time expires (shielding gas flows). • The arc is ignited (HF ignition). • The start current flows for the start time (the HF ignition shuts down).
Functional characteristics Welding programs cycle • Press the torch trigger 1 • The gas pre-flow time expires (shielding gas flows). • The arc is ignited (HF ignition). • The start current flows as long as the torch trigger is held, but at least for the start time (the HF ignition shuts down).
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Functional characteristics Welding programs Figure 5-19 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 5.2.4 chapter. Sequence: • Press torch trigger and hold down. • The gas pre-flow time elapses. •...
Functional characteristics Welding programs 5.2.5.5 spotmatic In contrast to the spotArc operating mode, the arc is not ignited by pressing the torch trigger as is usual, but by briefly touching the tungsten electrode against the workpiece. The torch trigger is used for welding process activation.
Functional characteristics Welding programs As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 5.2.4 chapter. Selecting the process activation type for the welding process > see 5.11 chapter. Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 s) only.
5.2.6 TIG activArc welding The EWM activArc process, thanks to the highly dynamic controller system, ensures that the power sup- plied is kept virtually constant in the event of changes in the distance between the welding torch and the weld pool, e.g. during manual welding. Voltage losses as a result of a shortening of the distance between the torch and molten pool are compensated by a current rise (ampere per volt - A/V), and vice versa.
Functional characteristics Welding programs 5.2.8 Pulse welding The f ollowing pulse types can be selected: • Average value pulsing (TIG AC up to 5 Hz and WIG DC up to 20 kHz) • Thermal pulsing (TIG AC or TIG DC) •...
Functional characteristics Welding programs 5.2.9.1 Thermal pulsing The operation sequences basically match the standard welding sequences, but there is an additional switching back and forth between the main current AMP (pulse current) and the secondary current AMP% (pulse pause current) at the set times. Pulse and pause times and the pulse edges ( ) are en- tered in seconds on the control.
Functional characteristics Welding programs 5.2.9.3 AC special Is e.g. used to join metal sheets of different thickness. Pulse time setting Figure 5-28 pulse edges can be set in the Expert menu (TIG) > see 5.2.12 chapter. 5.2.9.4 Pulsing in an upslope/downslope The pulse function can also be deactivated if necessary during the up-slope and down-slope phases (parameter ) >...
Functional characteristics Welding programs 5.2.10 Welding torch (operating variants) 5.2.10.1 Welding torch mode The operating elements (torch triggers or rockers) and their function can be individually adapted using various torch modes. Up to six modes are available to the user. The tables for the corresponding torch types describe the functional options.
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Functional characteristics Welding programs Welding torch with one torch trigger and up/down push-buttons Figure 5-32 Function Operation Mode Welding current On / Off BRT 1 Secondary current (in latched operation) Increase welding current (up/down speed) Decrease welding current (up/down speed) DOWN Welding current On / Off BRT 1...
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Functional characteristics Welding programs TIG function torch, Retox XQ Figure 5-34 Function Operation Mode Welding current On / Off BRT 1 Secondary current (in latched operation) Secondary current (in latched operation) BRT 2 Increase welding current (up/down speed) Decrease welding current (up/down speed) DOWN Welding current On / Off BRT 1...
Functional characteristics Welding programs Function Operation Mode Welding current On / Off BRT 1 Secondary current (in latched operation) Secondary current (in latched operation) BRT 2 Inf initely variable increase of welding current (up/down speed) Inf initely variable decrease of welding current (up/down speed) DOWN Switching between up/down speed and JOB number BRT 2...
Functional characteristics Welding programs 5.2.11 RTF 1 foot-operated remote control When the foot-operated remote control is connected, the machine switches automatically to non- latched operation. The up- and down-slopes are switched off. 5.2.11.1 Start ramp The start ramp function prevents an energy input that is too fast or too high immediately after the start of welding when the user depresses the pedal of the remote control too fast and too far.
Functional characteristics Welding programs 5.2.11.2 Responsiveness This f unction controls the responsiveness of the welding current during the main current phase. The user can choose between linear and logarithmic responsiveness. The logarithmic setting is particularly suitable f or welding with low current, e.g., for thin panels as the logarithmic responsiveness enables better control of the welding current.
Functional characteristics Welding programs 5.2.12 Expert menu (TIG) 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 f unction is deactivated. Figure 5-37 Display Setting/selection Slope time (main current to secondary current) Slope time (secondary current to main current) Amplitude balance >...
Functional characteristics Welding programs 5.2.13 Aligning the cable resistance To ensure optimum welding properties, the electric cable resistance should be aligned again whenever an accessory component such as the welding torch or the intermediate hose package (AW) has been chan- ged.
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Functional characteristics Welding programs 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle f rom the welding torch. • Unf asten the tungsten electrode and extract. • Switch on the welding machine. 2 Configuration • Press push-button •...
Functional characteristics MMA welding MMA welding 5.3.1 Welding task selection It is only possible to change the basic parameters when no welding current is flowing and any possible access control is disabled > see 5.8 chapter. The f ollowing welding task selection is an example of use. In general, the selection process always has the same sequence.
Functional characteristics MMA welding 5.3.3 Arcforce During the welding process, arcforce prevents the electrode sticking in the weld pool with increases in current. This makes it easier to weld large-drop melting electrode types at low current strengths with a short arc in particular. Arcforce Arcforce Figure 5-42...
Functional characteristics MMA welding 5.3.5 Welding current polarity reversal (polarity reversal) This f unction can be used to reverse the welding current polarity electronically. For example, when welding with different electrode types for which different polarities are stipulated by the manuf acturer, the welding current polarity can be switched easily on the control. Figure 5-44 5.3.6 AC welding...
Functional characteristics Arc length restriction (USP) Selection Figure 5-46 5.3.7 Pulse welding 5.3.7.1 Average value pulse welding Average value pulse welding means that two currents are switched periodically, a current average value (AMP), a pulse current (Ipuls), a balance ( ) and a f requency ( ) having been defined first.
Functional characteristics JOB f avourites 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. • Five Favourites are available to save any settings. •...
Functional characteristics Managing welding tasks (JOB manager) 5.5.3 Deleting saved Favourites Figure 5-51 • Press and hold the favourite memory push-button. Af ter 2 seconds, the signal light of the favourite status turns green af ter another 5 s, the signal light starts flashing red af ter another 5 s the signal light goes out •...
Functional characteristics Power-saving mode (Standby) 5.6.2 Reset welding task (JOB) to the factory setting This f unction resets the JOB data of a welding task (JOB) to be selected to the factory settings. Figure 5-53 Power-saving mode (Standby) You can activate the power-saving mode by either pressing the push-button > see 4 chapter for a prolon- ged time or by setting a parameter in the machine configuration menu (time-controlled power-saving mode ) >...
Functional characteristics Voltage reducing device Voltage reducing device The voltage reduction device (VRD) is used to increase safety, especially in dangerous environments (such as shipbuilding, pipeline construction, mining). The use of a voltage reduction device is mandatory in some countries and specified in many in-house saf ety regulations for welding power sources.
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Functional characteristics Machine configuration menu Display Setting/selection Exit the menu Exit Switching the machine off and on Required f or applying various configuration parameters Power source menu Switch ignition mode -------- HF ignition ------- Lif tarc HF intensity ------- Standard: Maximum value for the high-voltage ignition pulse Up ------- Reduced: Reduced value for the high-voltage ignition pulse Up Re-ignition after arc interruption >...
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Functional characteristics Machine configuration menu Display Setting/selection Machine display menu Setting the system of units ------- Units of length in mm, m/min. (metric system) ------- Unit of length in inches, ipm (imperial system) Absolute value setting (ignition, secondary, end and hot start cur- rent) >...
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Functional characteristics Machine configuration menu Display Setting/selection Alternative welding start – tapping start Available from torch mode 11 (welding stop by tapping remains active). -------- Function enabled (ex works) ------- Function disabled Tap end > see 5.2.10.2 chapter -------- Function enabled ------- Function disabled (factory setting) Up/down speed >...
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Functional characteristics Machine configuration menu Display Setting/selection Reset (to factory setting) ------- Disabled (ex works) ------- Reset the values in the machine configuration menu ------- Complete reset of all values and settings Resetting is performed when exiting the menu ( Software version query System bus ID and version number are separated by a dot.
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Functional characteristics Machine configuration menu Display Setting/selection Pulsed TIG welding (thermal) ------- Function enabled (ex works) ------- For special applications only Filler wire welding, operating mode -------- Filler wire operation for automated applications, wire is f ed when current flows -------- Non-latched operating mode (ex works) -------- 3rd cycle operating mode -------- Latched operating mode...
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.
Inf ormation 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 inf ormation 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.
Rectifying faults Warnings 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 Warnings Warning Potential cause / remedy 20 Coolant temperature warning Check coolant level and top up if necessary. 21 Excess temperature 2 reserved 22 Excess temperature 3 reserved 23 Excess temperature 4 reserved 24 Coolant flow warning Check coolant supply. Check coolant level and top up if necessary.
Rectifying faults Error messages (power source) Error messages (power source) The possible error numbers displayed depend on the machine series and version! Depending on the options of the machine display, a fault is shown as follows: Display type - machine control Display Graphic display two 7-segment displays...
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Rectifying faults Error messages (power source) Error 7: Low coolant level Category B Low f low rate. Fill with coolant. Check coolant flow - remove kinks in the hose package. Adjust the flow threshold Clean the cooler. ...
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Rectifying faults Error messages (power source) Error 16: Pilot-arc power source - collective error Category A The external emergency stop circuit has been interrupted. Check the emergency stop circuit and eliminate the cause of the error. The emergency stop circuit of the power source has been activated (internally configurable). Deactivate the emergency stop circuit.
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Rectifying faults Error messages (power source) Error 20: Low coolant level Category B Low f low rate. Fill with coolant. Check coolant flow - remove kinks in the hose package. Adjust the flow threshold Clean the cooler. ...
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Rectifying faults Error messages (power source) Error 32: Error I>0 Current recording is faulty. Request service. Error 33: Error UIST Voltage recording is faulty. Eliminate the short circuit in the welding circuit. Remove the external sensor voltage. ...
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Rectifying faults Error messages (power source) Error 48: Ignition error Category B No ignition at process start (automated machines). Check the wire f eeding Check the load cable connections in the welding circuit. Clean corroded surfaces on the workpiece before welding if necessary. ...
Rectifying faults Resetting welding parameters to the factory settings Error 57: Slave tacho error Category B Fault in the wire f eeder (slave drive). Check the connections (connectors, lines). Permanent overload of the wire drive (slave drive). Do not lay the liner in tight radii.
Appendix Parameter overview – setting ranges Appendix Parameter overview – setting ranges 8.1.1 TIG welding Name Display Setting range Gas pre-flow time Electrode diameter (metric) Electrode diameter (imperial) Ignition optimisation Start current (per cent of Start current (absolute, power source dependent) Start time 0,01 0,01...
Appendix Parameter overview – setting ranges 8.1.1.1 Pulse parameters Name Display Setting range Pulse current (average value pulsing) Pulse time (thermal pulsing) 0,01 0,00 20,0 Pulse pause time (thermal pulsing) 0,01 0,00 20,0 Pulse balance (average value pulsing, AC and DC) 50,0 99,9 Pulse frequency (average value pulsing, DC)
Appendix Parameter overview – setting ranges 8.1.2.1 Pulse parameters Name Display Setting range Pulse current (average value pulsing) Pulse balance (average value pulsing, AC and DC) 99,9 Pulse frequency (average value pulsing, DC) Pulse frequency (average value pulsing, AC) 8.1.2.2 AC parameters Name Display...
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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" 099-00T500-EW501 2.9.2022...
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