EWM DC Comfort 3.0 Operating Instructions Manual
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EWM DC Comfort 3.0 Operating Instructions Manual

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Operating instructions
Control
T5.01 - DC Comfort 3.0
EN
099-00T501-EW501
Observe additional system documents!
1.2.2023

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Summary of Contents for EWM DC Comfort 3.0

  • Page 1 Operating instructions Control T5.01 - DC Comfort 3.0 099-00T501-EW501 Observe additional system documents! 1.2.2023...
  • 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 Contents Notes on using these operating instructions 099-00T501-EW501 1.2.2023...

  • Page 4: Table Of Contents

    Contents Notes on using these operating instructions Contents 1 Contents ............................4 2 For your safety..........................6 Notes on using these operating instructions ................6 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ..................... 11 3 Intended use ..........................13 Use and operation solely with the following machines ............
  • Page 5 Contents Notes on using these operating instructions 5.1.11 Welding torch (operating variants) ............... 39 5.1.11.1 Welding torch mode ................39 5.1.11.2 Tapping function (tap torch trigger) ............42 5.1.11.3 Up/down speed ..................42 5.1.11.4 Current jump ..................42 5.1.12 RTF 1 foot-operated remote control ..............43 5.1.12.1 Working area ..................

  • Page 6: 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 7: Safety Instructions

    For your safety Safety instructions 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 Input Numerical value –...
  • Page 8 For your safety 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 9 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 10 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases may lead to shortness of breath and poisoning! The ultraviolet radia- tion of the arc may also convert solvent vapours (chlorinated hydrocarbon) into poiso- nous phosgene. • Ensure sufficient fresh air! •...

  • Page 11: 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 12 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 13: Intended Use

    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.

  • Page 14: 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 15: Part Of The Complete Documentation

    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.

  • Page 16: Machine Control - Operating Elements

    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 >...

  • Page 17: Control Section A

    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 5.10 chapter •...
  • Page 18 Machine control – Operating elements Overview of control sections Item Symbol Description Push-button for operating modes > see 5.1.7 chapter --------- Latched ------- Non-latched - Spot welding procedure spotArc Spot welding procedure spotmatic Pulsing push-button > see 5.1.10 chapter ------ Average value pulses ----- Thermal pulsing -- Automated pulsing Push-button gas test / rinse hose package >...

  • Page 19: Control Section B

    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) >...
  • Page 20 Machine control – Operating elements Overview of control sections Item Symbol Description Hold Signal light Status display After each completed welding task, the last values used in the welding process for the welding current and welding voltage are shown on the displays, and the signal light will be on Access control active signal light Signal light is on when access control is active on the machine con-...

  • Page 21: Control Section C

    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 Signal light for gas pre-flow time Signal light for ignition optimisation (TIG) Signal light for welding task (JOB)

  • Page 22: Machine Display

    Machine control – Operating elements Machine display Machine display The following 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 Before welding During welding...

  • Page 23: Setting Advanced Welding Parameters (Expert Menu)

    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 for which regular settings are not required. The number and display of these parameters depend on the previously selected welding procedure or functions.

  • Page 24: Functional Characteristics

    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. •...

  • Page 25: Welding Task Selection

    Functional characteristics TIG welding 5.1.2 Welding task selection By setting the tungsten electrode diameter , the TIG ignition behaviour (ignition energy), machine functions and minimum current limit are preset optimally. Smaller electrode diameters require less ignition energy than larger electrode diameters. If necessary, the ignition energy >...

  • Page 26: Manual Ignition Setting

    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 .

  • Page 27: Recurring Welding Tasks (Job 1-100)

    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.

  • Page 28: Welding Programs

    Functional characteristics TIG welding 5.1.5 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 5.10 chapter. In each selected welding task (JOB), > see 5.1.2 chapter, 16 programs can be set, saved and called up. In program “0”...

  • Page 29: Hf Ignition

    Functional characteristics TIG welding 5.1.6.1 HF ignition Figure 5-6 The arc is started without contact using high-voltage ignition pulses: a) Position the welding torch in the welding position above the workpiece (distance between the electrode tip and the workpiece approx. 2-3 mm). b) Press the torch trigger (high-voltage ignition pulses start the arc).

  • Page 30: Operating Modes (Functional Sequences)

    Functional characteristics TIG welding 5.1.7 Operating modes (functional sequences) 5.1.7.1 Explanation of symbols Symbol Meaning Press torch trigger 1 Release torch trigger 1 Current Time Gas pre-flow Start current Start time Up-slope time Spot time Main current (minimum to maximum current) Secondary current AMP% Pulse time...

  • Page 31: Non-Latched Mode

    Functional characteristics TIG welding 5.1.7.2 Non-latched mode Sequence Figure 5-8 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).

  • Page 32: Spotarc

    Functional characteristics TIG welding 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).
  • Page 33 Functional characteristics TIG welding Figure 5-11 As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 5.1.6 chapter. Sequence: • Press torch trigger and hold down. • The gas pre-flow time elapses. •...

  • Page 34: Spotmatic

    Functional characteristics TIG welding 5.1.7.5 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.

  • Page 35: Non-Latched Operation, Version C

    Functional characteristics TIG welding As an example the process is shown with HF ignition. Arc ignition with lift arc is also possible, how- ever > see 5.1.6 chapter. Selecting the process activation type for the welding process > see 5.10 chapter. Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 s) only.

  • Page 36: Tig Activarc Welding

    5.1.8 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.

  • Page 37: Pulse Welding

    Functional characteristics TIG welding 5.1.10 Pulse welding The following pulse types can be selected: • Average value pulses • Thermal pulsing • Automated pulsing 5.1.10.1 Average value pulse welding A special feature with average value pulses is that the power source will always maintain the preset average value.

  • Page 38: Thermal Pulsing

    Functional characteristics TIG welding 5.1.10.2 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.

  • Page 39: Pulsing In An Upslope/Downslope

    Functional characteristics TIG welding 5.1.10.4 Pulsing in an upslope/downslope The pulse function can also be deactivated if necessary during the up-slope and down-slope phases (parameter ) > see 5.10 chapter. Figure 5-20 5.1.11 Welding torch (operating variants) 5.1.11.1 Welding torch mode The operating elements (torch triggers or rockers) and their function can be individually adapted using various torch modes.
  • Page 40 Functional characteristics TIG welding Welding torch with two torch triggers or rocker Figure 5-22 Function Operation Mode Welding current On / Off BRT 1 Secondary current (in latched operation) BRT 2 Secondary current (in latched operation) BRT 1 Welding current On / Off BRT 1 Increase welding current (up/down speed) BRT 2...
  • Page 41 Functional characteristics TIG welding Welding torch with two torch triggers and up/down push-buttons Figure 5-24 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...

  • Page 42: Tapping Function (Tap Torch Trigger)

    Functional characteristics TIG welding Function Operation Mode Welding current On / Off BRT 1 Secondary current (in latched operation) Secondary current (in latched operation) BRT 2 Increase program number Decrease program number DOWN Switching between program and JOB BRT 2 Increase JOB number Decrease JOB number DOWN...

  • Page 43: Rtf 1 Foot-Operated Remote Control

    Functional characteristics TIG welding 5.1.12 RTF 1 foot-operated remote control Upon connection of the foot-operated remote control, the basic settings below apply: • The non-latched operating mode is activated (the operating modes latched, spotArc® and spot- matic are disabled). • Start/stop operation and the end program are deactivated.

  • Page 44: Start Program

    Functional characteristics TIG welding 5.1.12.3 Start program The start program “ ” can be enabled or disabled in the machine configuration menu > see 5.10 chapter. Enabled start program At the start of the process, the start program ensures the necessary arc stability until the main current “...

  • Page 45: Start/Stop Operation

    Functional characteristics TIG welding 5.1.12.5 Start/stop operation Start/stop operation “ ” can be enabled or disabled in the machine configuration menu > see 5.10 chapter. Enabled start/stop operation The foot-operated remote control is no longer used to specify the welding current, but rather starts or ends the welding process (see torch trigger).

  • Page 46: Aligning The Cable Resistance

    Functional characteristics TIG welding Display Setting/selection Remote control for lower current limit > see 5.1.12.1 chapter 5.1.14 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.
  • Page 47 Functional characteristics TIG welding 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle from the welding torch. • Unfasten the tungsten electrode and extract. • Switch on the welding machine. 2 Configuration • Press push-button • Press the rotary button and select parameter 3 Alignment / Measurement •...

  • Page 48: Mma Welding

    Functional characteristics MMA welding MMA welding 5.2.1 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 5.7 chapter. The following welding task selection is an example of use. In general, the selection process always has the same sequence.

  • Page 49: Arcforce

    Functional characteristics MMA welding 5.2.4 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 5-32...

  • Page 50: Pulse Welding

    Functional characteristics Arc length restriction (USP) 5.2.6 Pulse welding 5.2.6.1 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 frequency ( ) having been defined first.

  • Page 51: Saving Current Settings To Favourites

    Functional characteristics JOB favourites 5.4.1 Saving current settings to Favourites Figure 5-36 • Press and hold the favourite memory push-button for 2 s (the signal light of the favourite status is green). 5.4.2 Loading saved Favourites Figure 5-37 • Press the favourite memory push-button (the signal light of the favourite status is green). 5.4.3 Deleting saved Favourites Figure 5-38...

  • Page 52: Managing Welding Tasks (Job Manager)

    Functional characteristics Managing welding tasks (JOB manager) Managing welding tasks (JOB manager) 5.5.1 Copying welding tasks (JOB) Use this function to copy the JOB data of the currently selected JOB to a target -JOB to be specified. Figure 5-39 5.5.2 Reset welding task (JOB) to the factory setting This function resets the JOB data of a welding task (JOB) to be selected to the factory settings.

  • Page 53: Access Control

    Functional characteristics Access control Access control The machine control can be locked to secure it against unauthorised or unintentional adjustment. The access block has the following effect: • The parameters and their settings in the machine configuration menu, Expert menu and operation se- quence can only be viewed but not changed.

  • Page 54: Machine Configuration Menu

    Functional characteristics Machine configuration menu 5.10 Machine configuration menu Basic machine settings are defined in the machine configuration menu. 5.10.1 Selecting, changing and saving parameters Figure 5-41 Display Setting/selection Exit the menu Exit Switching the machine off and on Required for applying various configuration parameters Power source menu Switch ignition mode ------- HF ignition...
  • Page 55 Functional characteristics Machine configuration menu Display Setting/selection Reconditioning pulse (tungsten ball stability) Cleaning effect of the tungsten ball at the end of welding. ------ Function enabled (ex works) ------ Function disabled TIG HF start (soft/hard) switching ------ soft ignition (factory setting). ------ hard ignition.
  • Page 56 Functional characteristics Machine configuration menu Display Setting/selection Hold value (MMA) ------- Hold value is only displayed for a defined time (factory setting) ------- Function disabled Process menu spotmatic operating mode > see 5.1.7.5 chapter Ignition by contact with the workpiece ------- Function enabled (ex works) ------- Function disabled Spot time setting >...
  • Page 57 Functional characteristics Machine configuration menu Display Setting/selection Start JOB Set first retrievable JOB (setting: 1 to 100, factory setting 1). Remote control menu Responsiveness > see 5.1.12.2 chapter ------ Linear responsiveness ------ Logarithmic responsiveness (factory setting) Start program of foot-operated remote control > see 5.1.12.3 chapter ------ Function enabled (factory setting).
  • Page 58 Functional characteristics Machine configuration menu Display Setting/selection Operating time/arc time (resettable) ------- Display of the resettable operating time in hours and minutes (can be reset u- sing the parameter ------- Display of resettable arc time in hours and minutes (can be reset using the pa- rameter Operating time/arc time (total) ------- Display of the operating time in hours and minutes (total)
  • Page 59 Functional characteristics Machine configuration menu Display Setting/selection Welding current actual value display > see 4.2 chapter ------ Actual value display ------ Nominal value display 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 fed when current flows ------ Non-latched operating mode (ex works)

  • Page 60: 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 61: 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 62: Rectifying Faults

    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.
  • Page 63 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.

  • Page 64: Error Messages (Power Source)

    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...
  • Page 65 Rectifying faults Error messages (power source) Error 7: Low coolant level Category B  Low flow rate. Fill with coolant.  Check coolant flow - remove kinks in the hose package.  Adjust the flow threshold  Clean the cooler. ...
  • Page 66 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.
  • Page 67 Rectifying faults Error messages (power source) Error 20: Low coolant level Category B  Low flow rate. Fill with coolant.  Check coolant flow - remove kinks in the hose package.  Adjust the flow threshold  Clean the cooler. ...
  • Page 68 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. ...
  • Page 69 Rectifying faults Error messages (power source) Error 48: Ignition error Category B  No ignition at process start (automated machines). Check the wire feeding  Check the load cable connections in the welding circuit.  Clean corroded surfaces on the workpiece before welding if necessary. ...

  • Page 70: Resetting Welding Parameters To The Factory Settings

    Rectifying faults Resetting welding parameters to the factory settings Error 57: Slave tacho error Category B  Fault in the wire feeder (slave drive). Check the connections (connectors, lines).   Permanent overload of the wire drive (slave drive). Do not lay the liner in tight radii. ...

  • Page 71: Appendix

    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...

  • Page 72: Pulse Parameters

    Appendix Parameter overview – setting ranges 8.1.1.1 Pulse parameters Name Display Setting range Pulse current (average value pulses) 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 pulses) 50,0 99,9 Pulse frequency (average value pulses) 2,00 0,10...

  • Page 73: Global Parameters

    Appendix Parameter overview – setting ranges 8.1.3 Global parameters Name Display Setting range Standby Re-ignite after arc interruption Torch mode Up/down speed Current jump Retrieval of JOB number Start JOB Welding torch cooling, post-flow time Welding torch cooling, temperature error limit Welding torch cooling, temperature error limit (impe- rial) Welding torch cooling, flow error limit...

  • Page 74: Searching For A Dealer

    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" 099-00T501-EW501 1.2.2023...

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T5.01

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