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Operating instructions Control L1.01 - Expert 2.0 L1.02 - Expert 2.0 099-00L100-EW501 Observe additional system documents! 4.7.2019...
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+49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted.
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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 3 Intended use ............................
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Contents Notes on the use of these operating instructions 5.5.4.1 System......................36 5.5.4.2 Xnet machine ....................36 5.5.5 Load languages and texts .................... 36 5.5.6 Record on USB drive ....................36 5.5.6.1 Register USB drive ..................36 5.5.6.2 Start recording ....................36 5.5.6.3 Stop recording ....................
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Contents Notes on the use of these operating instructions 8 Appendix ............................... 78 JOB-List ............................78 Parameter overview – setting ranges ..................86 Searching for a dealer ......................... 88 099-00L100-EW501 4.7.2019...
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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. •...
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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 Switch Incorrect / Invalid Turn Correct / Valid Numerical value –...
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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.
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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 standards applicable for use in industry and trade. It may only be used for the welding procedures indicated at the rating plate.
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Quick overview Machine control – Operating elements Quick overview Machine control – Operating elements Figure 4-1 Item Symbol Description System push-button To display and configure the system settings > see 5.4.4 chapter. Machine display Graphical machine display showing all machine functions, menus and parameters with their values >...
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Quick overview Machine control – Operating elements Item Symbol Description Arc push-button This push-button has a double function: • Initial state of main screen: Switching of the welding procedure based on the select- ed material, gas and welding consumable. • Initial state of any sub-menu: Display switches back to the main screen.
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Quick overview Screen icons Screen icons Symbol Description Shielding gas Material type Wire inching Wire return Advanced settings Set-up mode Non-latched operating mode Special non-latched operating mode Latched operating mode Special latched operating mode Welding task superPuls superPuls switched off Interference Temperature error Spot welding operating mode...
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Quick overview Screen icons Symbol Description Save data to USB medium Load data from USB medium USB data recording Screen type 3/4, switching buttons Pulse arc welding Standard arc welding Welding procedure Refresh After welding, the last weld values (hold values) from the main program are displayed Information Welding current Welding voltage...
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Quick overview Screen icons 4.2.2 Main screen The main screen shows all the information relevant for the welding process before, while and after it is carried out. In addition, it shows status information on the machine state. The assignment of the context- dependent push-buttons is also shown on the main screen.
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Quick overview Screen icons 4.2.2.1 Main screen variants Main screen type 1 Main screen type 2 (ex works) Main screen type 3 Figure 4-3 You can select the required variant (type of main screen) in the Machine configuration (system) menu > see 5.4.6 chapter. 4.2.3 Initial screen During the start process the control name, machine software version and selected language are shown...
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Quick overview Screen icons 4.2.3.1 Basic settings for operation with two wire feeders (P10) The setting is available/required in the following cases only: • the control is integrated in the wire feeder • the control is integrated in the power source (compact design) Menu item/parameter Value Comment...
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Operating the machine control Welding power setting Operating the machine control In general the control is operated with the central control button below the machine display. Select the required menu item by turning (navigate) and pressing (confirm) the central control button. In addition, the context-dependent push-buttons below the machine display can be used for confirmation.
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Operating the machine control Machine configuration (system) Machine configuration (system) In the System menu the user can set the basic machine configuration. Enter the menu: Figure 5-1 5.4.1 Power-saving mode (Standby) There are three options to activate the power-saving mode: 1.
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Operating the machine control Machine configuration (system) 5.4.2 Access permission (Xbutton) The welding system offers two options to prevent unauthorised access to welding parameters or uninten- tional reconfiguration. 1 Key switch (available depending on machine version). With the key switch in position 1 all functions and parameters can be configured without any restriction.
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Operating the machine control Machine configuration (system) 5.4.3 Status information This menu provides the user with information on current system interferences and warnings.. 5.4.3.1 Errors and warnings Figure 5-3 Item Symbol Description Error number > see 7.4 chapter Error icons ------- Warning (prior to interference) ------- Interference (welding process will be stopped) ------- Specific (e.g.
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Operating the machine control Machine configuration (system) 5.4.4 System settings In this area the user can configure advanced system settings. 5.4.4.1 Date Menu item/parameter Value Comment Year: 2014 Month: Day: Date format: DD.MM.YYYY YYYY.MM.DD 5.4.4.2 Time Menu item/parameter Value Comment Hour: 0–24 Minute:...
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Operating the machine control Machine configuration (system) 5.4.4.4 Special parameter The special parameters of the wire feeder control are used to customize the machine function configurati- The number of selectable special parameters can deviate between the machine controls used in the welding system.
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Operating the machine control Machine configuration (system) Menu i- Value Comment tem/parameter Program settings for relative programs 0 =-------- Combined setting of relative programs possible (ex works). 1 =-------- Individual setting of relative programs possible. Operating mode switching at welding start 0 =-------- Not enabled (factory setting) 1 =-------- Enabled 30 %...
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Operating the machine control Machine configuration (system) Switching on/off correction operation (P7) The correction operation is switched on and off for all JOBs and their programs at the same time. A cor- rection operation is specified for wire speed (DV) and welding voltage correction (Ukorr) for each JOB. The correction value is saved separately for each program.
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Operating the machine control Machine configuration (system) Program switching with standard welding torch (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". •...
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Operating the machine control Machine configuration (system) Specific latched special (n cycle) In the n cycle program sequence, the unit starts in the 1st cycle with start program P from P start In the second cycle, the machine switches to absolute program 2, once the start time "tstart" has elapsed. Tapping switches to other programs (P to max.
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Operating the machine control Machine configuration (system) Set special latched tapping time (P11) The tapping time for changing over between the main program and reduced main program can be set in three levels. 0 = no tapping 1 = 320ms (factory setting) 2 = 640ms JOB list switching (P12) Value...
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Operating the machine control Machine configuration (system) Block JOB mode (P16) The following accessory components support block JOB mode: • Up/Down welding torch with one-digit 7-segment display (two keys) Program 0 is always active in JOB 0 and program 1 in all other JOBs In this operating mode, up to 30 JOBs (welding tasks) divided into three blocks can be called up with ac- cessory components.
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Operating the machine control Machine configuration (system) Operating mode switching at welding start (P27) With the selected 4-cycle-Special mode, the user can determine by the time of the torch trigger operation in which operating mode (4-cycle or 4-cycle-Special) the program sequence shall be carried out. Hold torch trigger (longer than 300 ms): Program sequence with operating mode 4-cycle-Special (stan- dard).
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Operating the machine control Machine configuration (system) 5.4.6 Operating panel settings Menu item/parameter Value Comment Main screen Autom. selection of welding power Off–30 s Display brightness: 0–100% Display contrast: 0–100% Display negative: Non-latched operation available Latched operation available Special non-latched operation available Spot welding selectable available Special latched operation available P0 of Expert 2.0 can be changed:...
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Operating the machine control Machine configuration (system) 5.4.7 Aligning the cable resistance The resistance value of cables can either be set directly or it can be aligned using the power source. The factory setting of the power sources is 8 mΩ. This value correponds to a 5 m earth cable, a 1.5 m inter- mediate hose package and a 3 m water-cooled welding torch.
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Operating the machine control Machine configuration (system) 50mm DE - Abgleich Leitungswiderstand EN - Cable resistance alignment FR - Alignement résistance ligne IT - Compensazione resistenza circuito ES - Compensación de la resistencia del cable NL - Compensatie leidingsweerstand SE - Kalibrering av ledningsmotståndet PL - Porównanie rezystancji przewodu RU - Компенсация...
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The message can be reset and a new QR code may be requested from the network. 5.4.7.3 Component identification Bar codes predefined in ewm Xnet are recorded with a manual scanner. Component data are retrieved and displayed in the control. Figure 5-9...
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Operating the machine control Offline data transfer (USB) 5.4.7.5 Errors and warnings A list of all ewm Xnet-specific errors and warnings are displayed with their ID number and description. 5.4.8 Status information Figure 5-11 5.4.8.1 Network Figure 5-12 5.4.9 Clear system memory Resets the internal system memory used for saving welding and log data and deletes all data.
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Operating the machine control Offline data transfer (USB) Offline data transfer (USB) You may only use this USB interface to exchange data with a USB flash memory. You must not connect any other USB devices such as keyboards, hard disks, mobile telephones, cameras or other devices so as to avoid any damage tp the machine.
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Operating the machine control Offline data transfer (USB) 5.5.4 Load configuration 5.5.4.1 System Configuration data of the power source’s system components. 5.5.4.2 Xnet machine Master configuration Core date for network communication (independent of machine). Individual configuration Machine-related configuration data, matching the current power source only. 5.5.5 Load languages and texts Load a language and text package from the storage medium (USB) to the welding machine.
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Operating the machine control Welding task administration (Menu) Welding task administration (Menu) In this menu the user can carry out all welding task (JOB) organisation operations. 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 shiel- ding gas type have been predefined >...
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Operating the machine control Welding task administration (Menu) 5.6.3 Program sequence In the program sequence, you can select welding parameters and set their values. The number of para- meters shown depends on the selected operating mode. In addition, the user can access advanced settings and the setup mode. The setting range for the parameter values are summarised in the parameter overview section >...
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Operating the machine control Welding task administration (Menu) 5.6.3.1 Programs (P 1-15) In the manual program P0, the user can adjust the operating point in a conventional way using the para- meter settings on the machine control. The active program is shown in the main menu of the machine display in the display area for process parameters with the letter “P”...
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Operating the machine control Welding task administration (Menu) 5.6.3.2 Overview of the welding parameter switching options The user can change the welding parameters of the main programs with the following components. M3.7 – I/J Wire feeder control P1-15 PC 300.NET Software P1-15 MT Up/Down...
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Operating the machine control Welding task administration (Menu) Example 2: Welding different positions on a workpiece (latched) Figure 5-18 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-19 099-00L100-EW501 4.7.2019...
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Operating the machine control Welding task administration (Menu) 5.6.3.3 MIG/MAG welding In every JOB, separate settings can be made for the ignition program, reduced main program and end program as to whether or not to alternate with the pulse process. These properties are stored on the welding machine with the JOB.
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Operating the machine control Welding task administration (Menu) 5.6.3.4 Advanced settings Menu item/parameter Value Comment Process switching Start program pulsing End program pulsing Wire retraction ignition Lift arc (PP) Lift arc End pulse duration 0.0–20 ms U correction limit 0.0–9.9 V Applies with correction operation enabled Wire correction limit 0–30%...
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Operating the machine control Welding task administration (Menu) 5.6.3.5 TIG welding Figure 5-21 Menu item/parameter Program Comment Gas pre-flow time Gas nominal value GFE option/variant (electronic gas volume con- trol) required Current Ignition current START Duration Duration (start program) Slope time Slope duration from P to P START...
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Operating the machine control Welding task administration (Menu) 5.6.3.6 MMA welding Figure 5-22 Menu item/parameter Comment Current Hot start current Duration Hot start time Current Main current The hotstart current is a percentage based on the welding current selected. 099-00L100-EW501 4.7.2019...
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Operating the machine control Welding task administration (Menu) 5.6.4 Setup mode Figure 5-23 Item Symbol Description Wire return Results in reverse inching of the wire. Pressing the push-button longer will increase the wire reversing speed. Wire inching The wire is inched into the hose package. Pressing the push-button longer will increase the wire inching speed.
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Operating the machine control Welding task administration (Menu) 5.6.5 WPQR welding data assistant The cooling-down time from 800°C to 500°C essential for the welding result (known also as t8/5 time) can be calculated using the input data in the WPQR welding data assistant. Prerequisite is the prior determi- nation of the heat input.
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Operating the machine control Welding task administration (Menu) 5.6.6 Welding monitoring Figure 5-24 Item Symbol Description Current tolerance WF tolerance Voltage tolerance Advanced settings Display and setting of advanced system parameters > see 4.2.3 chapter WPQR welding data assistant WPQR Menu item / parameter Value Comment...
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Operating the machine control Change welding procedure (Arc) Change welding procedure (Arc) In this menu the user can change the welding procedure based on the preselected material, wire and gas (change of process based on welding task). For changing the welding task (JOB) > see 5.6 chapter Enter the menu: Figure 5-25 Online data transfer (network)
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Operating the machine control Online data transfer (network) 5.8.2 Wireless local network (WiFi) Status description Status display No physical connection to a network Deactivated WiFi symbol Connection to a network, no data transfer Activated WiFi symbol Connection to a network, transferring data WiFi symbol flashing Connection to the network, the machine has been LAN symbol flashing in the specified rhythm...
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Welding procedure MIG/MAG welding Welding procedure The welding task is selected in the JOB selection menu (material/wire/gas) > see 5.6.1 chapter. The basic settings of the relevant welding procedure, such as operating mode or arc length correction, can be selected on the main screen on the process parameter panel > see 4.2.2 chapter. The program sequence settings are set in the program sequence menu >...
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(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 selec- ting program 1 >...
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Welding procedure MIG/MAG welding Non-latched mode Figure 6-1 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
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Welding procedure MIG/MAG welding Non-latched operation with superpulse Figure 6-2 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
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Welding procedure MIG/MAG welding Special, non-latched Figure 6-3 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P for the time t START...
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Welding procedure MIG/MAG welding Spot welding Figure 6-4 The ignition time t must be added to the spot time t start 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed" •...
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Welding procedure MIG/MAG welding Special, non-latched with superpulse Figure 6-5 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P for the time t START...
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Welding procedure MIG/MAG welding Latched mode Figure 6-6 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
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Welding procedure MIG/MAG welding Latched mode with superpulse Figure 6-7 Step 1: • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
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Welding procedure MIG/MAG welding Latched with changing welding method (process switching) Exclusively for devices with pulsed arc welding type > see 3.2 chapter. Figure 6-8 1st cycle: • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) •...
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Welding procedure MIG/MAG welding Latched special Figure 6-9 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P START Step 2...
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Welding procedure MIG/MAG welding Special latched with changing welding method by tapping (process switching) Exclusively for devices with pulsed arc welding type > see 3.2 chapter. Figure 6-10 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) •...
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Welding procedure MIG/MAG welding Special latched with changing welding method (process switching) Exclusively for devices with pulsed arc welding type > see 3.2 chapter. Figure 6-11 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) •...
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Welding procedure MIG/MAG welding Special, latched with superpulse Figure 6-12 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P for the time t START...
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Welding procedure MIG/MAG welding 6.1.8 coldArc / coldArc puls Heat-reduced, low-spatter short arc for high dimensional stability welding and brazing of thin metal sheets with excellent gap-bridging. Figure 6-13 After selecting the coldArc process > see 5.6 chapter you benefit from: •...
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(molten metal) decreases and the penetration reduces. Figure 6-16 With the EWM wiredArc arc with wire control, the welding current (AMP) changes with the change of the stick-out only slightly. The compensation of the welding current takes place with an active control of wire feed speed (DG).
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Welding procedure MIG/MAG welding 6.1.12 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 Additional functions such as program switching (before or after welding) are possible by tapping the torch trigger (depending on machine type and control configuration).
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Welding procedure TIG welding TIG welding 6.2.1 Operating modes (functional sequences) 6.2.1.1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger (press briefly and release) Shielding gas flowing Welding output Gas pre-flows Gas post-flows Non-latched Special, non-latched Latched...
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Welding procedure TIG welding Non-latched mode Figure 6-18 Selection • Select non-latched operating mode Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). The arc is ignited using liftarc. • Welding current flows with pre-selected setting. Step 2 •...
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Welding procedure TIG welding Latched mode Figure 6-20 Selection • Select latched operating mode Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) The arc is ignited using liftarc. • Welding current flows with pre-selected setting. Step 2 •...
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Welding procedure TIG welding Latched special Figure 6-21 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 ".
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Welding procedure TIG welding 6.2.2 Arc ignition 6.2.2.1 Liftarc Figure 6-22 The arc ignites through contact with the workpiece: a) Carefully place the torch gas nozzle and tungsten electrode tip against the workpiece (lift arc current flows independent of the set main current) b) Angle the torch above the torch gas nozzle until the distance between electrode tip and workpiece is approx.
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Welding procedure MMA welding MMA welding 6.3.1 Hotstart The function hot start ensures a secure igniting of the arc and a sufficient heating to the still cold parent metal at the beginning of the welding process. The ignition takes place here with increased current (hot start current) over a certain time (hot start time).
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Rectifying faults Resetting JOBs (welding tasks) to the factory settings 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 Warnings Depending on the display options of the machine display, a warning message is displayed as follows: Display type - machine control Display Graphic display two 7-segment displays one 7-segment display The cause of the warning is indicated by a corresponding warning number (see table). •...
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Rectifying faults Error messages Error messages A welding machine error will be signalled by an error code (see table) on the control display. In the event of an error, the power unit shuts down. The display of possible error numbers depends on the machine version (interfaces/functions). •...
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Rectifying faults Error messages 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 context-dependent push-button with the icon. c) The error message can only be reset by switching the machine off and on again. 099-00L100-EW501 4.7.2019...
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Appendix JOB-List Appendix JOB-List Procedure Material Ø [mm] GMAW standard G3Si1 / G4Si1 CO2 100 (C1) GMAW standard G3Si1 / G4Si1 CO2 100 (C1) GMAW standard G3Si1 / G4Si1 CO2 100 (C1) GMAW standard G3Si1 / G4Si1 CO2 100 (C1) GMAW standard G3Si1 / G4Si1 CO2 100 (C1)
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Appendix Parameter overview – setting ranges Parameter overview – setting ranges Parameter Setting range Comment MIG/MAG Gas pre-flow time Gas nominal value l/min. GFE option Start program P START WF relative Duration 0,00 - 20,0 U correction -9,9 Slope time 0,00 20,0 Main program P...
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Appendix Parameter overview – setting ranges Parameter Setting range Comment Hot start current Hot start time -10,0 Arcforce 099-00L100-EW501 4.7.2019...
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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" 099-00L100-EW501 4.7.2019...
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