EWM Control HP-XQ Operating Instructions Manual
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EWM Control HP-XQ Operating Instructions Manual

EWM Control HP-XQ Operating Instructions Manual

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Operating instructions
Control
HP-XQ (M3.7X-I)
EN
099-00HPXQ-EW501
Observe additional system documents!
07.05.2021

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Summary of Contents for EWM Control HP-XQ

  • Page 1 Operating instructions Control HP-XQ (M3.7X-I) 099-00HPXQ-EW501 Observe additional system documents! 07.05.2021...
  • 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 ..........................6 Notes on using these operating instructions ................6 Explanation of icons ....................... 7 Safety instructions ........................8 Transport and installation ....................11 3 Intended use ..........................
  • Page 4 Contents Notes on using these operating instructions 5.4.20 MIG/MAG special-torches ..................54 5.4.20.1 Program and up/down operation ............54 5.4.20.2 Switching between Push/Pull and intermediate drive ......55 TIG welding .......................... 55 5.5.1 Welding task selection ..................55 5.5.1.1 Welding current setting ................55 5.5.2 Arc ignition ......................
  • Page 5 Contents Notes on using these operating instructions 5.11 Machine configuration menu ....................75 5.11.1 Selecting, changing and saving parameters ............75 5.11.2 Aligning the cable resistance ................76 5.12 Power-saving mode (Standby) .................... 77 6 Rectifying faults ........................... 78 Display machine control software version ................78 Error messages (power source) ..................

  • 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: 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 Correct / Valid...

  • Page 8: 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 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 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 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: Part Of The Complete Documentation

    Intended use Part of the complete documentation 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 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 16: Control Section A

    Machine control – Operating elements Overview of control sections 4.1.1 Control section A Figure 4-2 Item Symbol Description Welding task push-button (JOB) • ---------- Pressing the pushbutton briefly: Fast switching of the available welding proce- dures in the selected basic parameters (material/wire/gas). •...

  • Page 17: Control Section B

    Machine control – Operating elements Overview of control sections Item Symbol Description Correction of arc length with click wheel • ----------- Setting the correction of arc length > see 5.4.6.2 chapter • ----------- Setting the arc dynamics > see 5.4.6.3 chapter •...

  • Page 18: Control Section C

    Machine control – Operating elements Overview of control sections Item Symbol Description End program signal light End --------- Wire feed speed (percent of main program P Arc length correction -------- --------- End current time "t10" Start and end programs are only active in the 2- and 4-cycle Special modes. Gas post-flow time signal light Select welding parameters button This button is used to select the welding parameters depending on the welding process...
  • Page 19 Machine control – Operating elements Overview of control sections Item Symbol Description Correction voltage arc length signal light Display of correction voltage arc length in volts. Welding power signal light Display of welding power in kilowatts. Electronic gas flow control signal light OW DGC > see 5.7.1 chapter Shows the gas flow rate in the device display.

  • Page 20: Welding Data Display

    Machine control – Operating elements Welding data display Welding data display On the left and right of the parameter displays there are push-buttons for the selection of parameters. They are used to select the welding parameters to be displayed and their values. Each time one the button is clicked, the display proceeds to the next parameter (signal lights indicate the selection).

  • Page 21: Operating The Machine Control

    Machine control – Operating elements Operating the machine control Operating the machine control 4.3.1 Main screen The machine control switches to the main screen after it has been turned on or a setting has been com- pleted. This means that the previously selected settings (indicated by signal lights where applicable) and the nominal value for the current (A) are displayed in the left-hand welding data display.

  • Page 22: 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 which cannot be set directly in the machine control or which do not need to be et on a regular basis. The number and display of these parameters depends on the previously selected welding procedure or the functions.

  • Page 23: Functional Characteristics

    Functional characteristics Shielding gas volume settings Functional characteristics Shielding gas volume settings If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause pores to form. Adjust the shielding gas quantity to suit the welding task! •...

  • Page 24: Wire Thread

    Functional characteristics Wire thread Wire thread The wire inching function is used for potential- and gas-free inching of the wire electrode after the wire spool change. By pressing and holding the wire inching button for a long time, the wire inching speed in- creases in a ramp function (special parameter P1 >...

  • Page 25: Mig/Mag Welding

    Functional characteristics MIG/MAG welding MIG/MAG welding 5.4.1 Welding task selection The following steps have to be carried out to select the welding job: • Select basic parameters (material type, wire diameter and shielding gas type) and welding procedures (select and enter JOB number by means of JOB-List > see 7.1 chapter). •...

  • Page 26: Welding Procedure

    Functional characteristics MIG/MAG welding 5.4.3 Welding procedure After setting the basic parameters you can switch between the welding procedures MIG/MAG, forceArc, wiredArc, rootArc und coldArc (if there is a corresponding combination of the basic parameters). The pro- cess change will also change the JOB number, but the basic parameters remain unchanged. Figure 5-6 5.4.4 Operating mode...

  • Page 27: Welding Type

    Functional characteristics MIG/MAG welding 5.4.5 Welding type Different forms of MIG/MAG processes are referred to as welding type. Standard (Welding with standard arc) Depending on the set combination of wire feed speed and arc voltage, the arc types short arc, transitional arc or spray arc can be used for welding.

  • Page 28: Welding Power (Operating Point)

    Functional characteristics MIG/MAG welding 5.4.6 Welding power (operating point) The welding power is adjusted according to the principle of one-knob operation. The user can set their operating point optionally as wire feed speed, welding current or material thickness. The optimum welding voltage for the operating point is calculated and set by the welding machine.

  • Page 29: Arc Length

    Functional characteristics MIG/MAG welding 5.4.6.2 Arc length When required, the arc length (welding voltage) can be adjusted for the welding task in hand by +/– 9.9 V. Figure 5-10 5.4.6.3 Arc dynamics (choke effect) This function can be used to adjust the arc between a narrow, hard arc with deep penetration (positive values) and a wide and soft arc (negative values).

  • Page 30: Superpuls

    Functional characteristics MIG/MAG welding 5.4.7 superPuls In superPuls mode, the program toggles between the main program (PA) and the reduced main program (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.

  • Page 31: Copy Job (Welding Task)

    Functional characteristics MIG/MAG welding 5.4.8 Copy JOB (welding task) Figure 5-13 099-00HPXQ-EW501 07.05.2021...

  • Page 32: Expert Menu (Mig/Mag)

    Functional characteristics MIG/MAG welding 5.4.9 Expert menu (MIG/MAG) 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 function is deactivated. Figure 5-14 Display Setting/selection Burn-back time > see 5.4.10 chapter •...

  • Page 33: Burn-Back

    Functional characteristics MIG/MAG welding Display Setting/selection Pulse arc welding process (program P START The pulse arc welding process can be activated in the start program (P ) with the START special non-latched and special latched operating modes. -------Function activated. -------Function deactivated. Pulse arc welding process (program P The pulse arc welding process can be activated in the end program (P ) with the spe-...

  • Page 34: Programme Limit

    Functional characteristics MIG/MAG welding 5.4.11 Programme limit The JOB-dependent program limit allows you to limit the number of programs that can be selected in the selected JOB to (2...9). This option can be set individually per JOB. In addition, a legacy option to set a "global program limit"...

  • Page 35: Selection And Adjustment

    Functional characteristics MIG/MAG welding 5.4.12.1 Selection and adjustment Figure 5-15 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 Welding torch P1-9 MT 2 Up/Down Welding torch...
  • Page 36 Functional characteristics MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-16 Example 2: Welding different positions on a workpiece (latched) Figure 5-17 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-18 Up to 16 programs (P to P...

  • Page 37: Program Sequence

    Functional characteristics MIG/MAG welding 5.4.13 Program sequence Certain materials, aluminium for example, require special functions for reliable and high-quality welding. In this case, the special latched mode is used with the following programs: • Start program P (avoidance of cold welds at start of seam) START •...

  • Page 38: Setting

    Functional characteristics MIG/MAG welding 5.4.13.2 Setting Figure 5-21 099-00HPXQ-EW501 07.05.2021...

  • Page 39: Operating Modes (Functional Sequences)

    Functional characteristics MIG/MAG welding 5.4.14 Operating modes (functional sequences) There are optimum pre-sets for welding parameters such as gas pre-flow and burn back, etc. for numerous applications (although these can also be changed if required). 5.4.14.1 Explanation of signs and functions Symbol Meaning Press torch trigger...
  • Page 40 Functional characteristics MIG/MAG welding Non-latched mode Figure 5-22 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 41 Functional characteristics MIG/MAG welding Non-latched operation with superpulse Figure 5-23 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 42 Functional characteristics MIG/MAG welding Special, non-latched Figure 5-24 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P for the time t START...
  • Page 43 Functional characteristics MIG/MAG welding Spot welding Figure 5-25 The ignition time t must be added to the spot time t start 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed" •...
  • Page 44 Functional characteristics MIG/MAG welding Special, non-latched with superpulse Figure 5-26 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P for the time t START...
  • Page 45 Functional characteristics MIG/MAG welding Latched mode Figure 5-27 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 46 Functional characteristics MIG/MAG welding Latched mode with superpulse Figure 5-28 Step 1: • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 47 Functional characteristics MIG/MAG welding Latched with changing welding method (process switching) To activate or set the function > see 5.4.9 chapter. Figure 5-29 1st cycle: • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed" •...
  • Page 48 Functional characteristics MIG/MAG welding Latched special Figure 5-30 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P START Step 2...
  • Page 49 Functional characteristics MIG/MAG welding Special latched with changing welding method by tapping (process switching) To activate or set the function > see 5.4.9 chapter. Figure 5-31 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) •...
  • Page 50 Functional characteristics MIG/MAG welding Special latched with changing welding method (process switching) To activate or set the function > see 5.4.9 chapter. Figure 5-32 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed"...
  • Page 51 Functional characteristics MIG/MAG welding Special, latched with superpulse Figure 5-33 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P for the time t START...

  • Page 52: Forcearc / Forcearc Puls

    Functional characteristics MIG/MAG welding 5.4.15 forceArc / forceArc puls Heat-reduced, directionally-stable and powerful arc with deep fusion penetration for the upper power range. Figure 5-34 • Smaller included angle due to deep penetration and directionally stable arc • Excellent root and sidewall fusion •...

  • Page 53: Wiredarc

    (molten metal) decreases and the penetration reduces. Figure 5-35 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).

  • Page 54: Coldarc / Coldarc Puls

    Functional characteristics MIG/MAG welding 5.4.18 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 5-38 After selecting the coldArc process > see 5.4.1 chapter you benefit from: •...

  • Page 55: Switching Between Push/Pull And Intermediate Drive

    Functional characteristics TIG welding 5.4.20.2 Switching between Push/Pull and intermediate drive WARNING Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. •...

  • Page 56: Arc Ignition

    Functional characteristics TIG welding 5.5.2 Arc ignition 5.5.2.1 Liftarc Figure 5-42 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.

  • Page 57: Automatic Cut-Out

    Functional characteristics TIG welding 5.5.3.2 Automatic cut-out Once the fault periods have elapsed, the automatic cut-out stops the welding process when it has been triggered by one of two states: • During ignition 5 s after the start of the welding process, no welding current flows (ignition error). •...
  • Page 58 Functional characteristics TIG welding Special, non-latched Figure 5-44 Selection • Select non-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 with pre-selected setting in start program “P ”.
  • Page 59 Functional characteristics TIG welding Latched mode Figure 5-45 Selection • Select latched operating mode Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) The arc is ignited using liftarc. • Welding current flows with pre-selected setting. Step 2 •...
  • Page 60 Functional characteristics TIG welding Latched special Figure 5-46 Selection • Select latched special mode Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). The arc is ignited using liftarc. • Welding gas flows at pre-selected setting in start program "P ".

  • Page 61: Mma Welding

    Functional characteristics MMA welding MMA welding 5.6.1 Welding task selection Figure 5-47 5.6.1.1 Welding current setting Figure 5-48 5.6.2 Arcforce Figure 5-49 Setting: • Negative values: rutile electrode types • Values at zero: basic electrode types • Positive values: cellulose electrode types 099-00HPXQ-EW501 07.05.2021...

  • Page 62: Hotstart

    Functional characteristics MMA welding 5.6.3 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).

  • Page 63: Options (Additional Components)

    Functional characteristics Options (additional components) Options (additional components) 5.7.1 Electronic gas flow control (OW DGC) The connected gas line has to have a preset pressure of 3–5 bar. The electronic gas flow control (DGC) regulates the optimum gas flow rate for the respective welding pro- cess (optimally preset from the factory).

  • Page 64: Selecting, Changing And Saving Parameters

    Functional characteristics Special parameters (advanced settings) 5.10.1 Selecting, changing and saving parameters Figure 5-54 Display Setting/selection Wire inching / wire return ramp time 0 = ------- normal inching (10 s ramp time) 1 = ------- fast inching (3 s ramp time) (ex works) Block program "0"...
  • Page 65 Functional characteristics Special parameters (advanced settings) Display Setting/selection Correction operation, threshold value setting 0 = --------correction operation switched off (Ex works) 1 = --------correction operation on "Main program (PA)" flashing Program switching with standard welding torch No program switching (factory setting) 1 = --------Special latched 2 = --------Special latched (n-cycle active) 3 = --------Special latched (n-cycle sequence from any program)

  • Page 66: Ramp Time For Wire Inching (P1)

    Functional characteristics Special parameters (advanced settings) Display Setting/selection Electronic gas flow control, type 1 = ------- type A (ex works) 0 = ------- type B Program settings for relative programs 0 = ------- Combined setting of relative programs possible (ex works). 1 = ------- Individual setting of relative programs possible (ex works).

  • Page 67: Special Cycle In The Operating Modes Special Latched And Non-Latched (P5)

    Functional characteristics Special parameters (advanced settings) 5.10.1.5 Special cycle in the operating modes special latched and non-latched (P5) With the special sequence activated, the start of the welding process changes as follows: Sequence for special non-latched mode/special latched mode: • Start program "P "...
  • Page 68 Functional characteristics Special parameters (advanced settings) Setting the correction range: • Activate the special parameter “Correction operation” (P7=1) and save > see 5.10.1 chapter. • Key switch to position . • Set the correction range as follows: Figure 5-56 • If the user is inactive for about 5 seconds, the pre-set values will be applied and the display switches back to the program display.

  • Page 69: Switching Programs With The Standard Torch Trigger (P8)

    Functional characteristics Special parameters (advanced settings) 5.10.1.7 Switching programs with the standard torch trigger (P8) Special latched (latched absolute program sequence) • Cycle 1: absolute program 1 is run • Cycle 2: absolute program 2 is run after completion of "tstart". •...

  • Page 70: Latched/Special-Latched Tap Start (P9)

    Functional characteristics Special parameters (advanced settings) The number of programs (P ) corresponds to the cycle number specified under N cycle. 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". •...

  • Page 71: Job List Switching (P12)

    Functional characteristics Special parameters (advanced settings) 5.10.1.11 JOB list switching (P12) Name Explanation Task-based JOB numbers are sorted by welding wires and shielding gases. When JOB list selecting, the JOB numbers may be skipped. JOB numbers correspond to the actual memory cells. Every job can Real JOB list be selected, there will be no memory cells if the selection will be skip- ped.

  • Page 72: Block Job Mode (P16)

    Functional characteristics Special parameters (advanced settings) 5.10.1.14 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.

  • Page 73: Predefined Execution Of The Pulsed Arc Welding Process In The Pa Program (P20)

    Functional characteristics Special parameters (advanced settings) 5.10.1.17 Predefined execution of the pulsed arc welding process in the PA program (P20) For machine versions with pulsed arc welding procedures only. Function active (P20 = 1) • If the superPuls and welding process switching functions are available and activated, the pulse arc welding process is always executed in the main program PA (ex factory).

  • Page 74: Selection Option - Program Sequence With Welding Power Rotary Knob (P30)

    Functional characteristics Special parameters (advanced settings) 5.10.1.27 Selection option – Program sequence with welding power rotary knob (P30) Function not active • The rotary knob is locked, use the welding parameters push-button to select the welding parameters. Function active • Rotary knob can be used to select the welding parameters.

  • Page 75: Machine Configuration Menu

    Functional characteristics Machine configuration menu 5.11 Machine configuration menu 5.11.1 Selecting, changing and saving parameters Changes to the welding parameters are only possible if the key switch is set to key position If the Xbutton function is activated, the key switch function is deactivated (see corresponding operating instructions "Control").

  • Page 76: Aligning The Cable Resistance

    Functional characteristics Machine configuration menu 5.11.2 Aligning the cable resistance The resistance value of cables can either be set directly or it can be aligned using the power source. The factory setting of the power sources is 8 mΩ. This value correponds to a 5 m earth cable, a 1.5 m inter- mediate hose package and a 3 m water-cooled welding torch.

  • Page 77: Power-Saving Mode (Standby)

    Functional characteristics Power-saving mode (Standby) 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle from the welding torch. • Trim the welding wire so that it is flush with the contact tip. • Retract the welding wire a little (approx. 50 mm) on the wire feeder. There should now be no more welding wire in the contact tip.

  • Page 78: Rectifying Faults

    Rectifying faults Display machine control software version 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 79 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. Adjust flow threshold. [1] [3] Clean water block. Pump does not turn Turn the pump shaft.
  • Page 80 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 81: 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 82 Rectifying faults Warnings Warning Possible cause / remedy 8 Welding circuit The welding circuit inductance 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, coolant Check temperature and switching thresholds.

  • Page 83: Resetting Jobs (Welding Tasks) To The Factory Settings

    Rectifying faults Resetting JOBs (welding tasks) to the factory settings only for XQ machine series See technical data for values and other switching thresholds. Resetting JOBs (welding tasks) to the factory settings All customised welding parameters that are stored will be replaced by the factory settings. 6.4.1 Resetting a single JOB Figure 6-1...

  • Page 84: Appendix

    Appendix JOB-List Appendix JOB-List JOB no. Processes Material Diameter [mm] GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 Standard GMAW / pulse...
  • Page 85 Appendix JOB-List JOB no. Processes Material Diameter [mm] Standard GMAW / pulse CrNi 22 9 3 / 1.4462 Ar-78 / He-20 / CO2-2 (M12) coldArc / coldArc puls CrNi 19 9 / 1.4316 Ar-97.5 / CO2-2.5 (M12) coldArc / coldArc puls CrNi 19 9 / 1.4316 Ar-97.5 / CO2-2.5 (M12) coldArc / coldArc puls...
  • Page 86 Appendix JOB-List JOB no. Processes Material Diameter [mm] Standard GMAW / pulse CuSi Ar-97.5 / CO2-2.5 (M12) Standard GMAW / pulse CuSi Ar-97.5 / CO2-2.5 (M12) Standard GMAW / pulse CuAl Ar-100 (I1) Standard GMAW / pulse CuAl Ar-100 (I1) Standard GMAW / pulse CuAl Ar-100 (I1)
  • Page 87 Appendix JOB-List JOB no. Processes Material Diameter [mm] Block 2/ JOB2 Block 2/ JOB3 Block 2/ JOB4 Block 2/ JOB5 Block 2/ JOB6 Block 2/ JOB7 Block 2/ JOB8 Block 2/ JOB9 Block 2/ JOB10 Block 3/ JOB1 Block 3/ JOB2 Block 3/ JOB3 Block 3/ JOB4 Block 3/ JOB5...
  • Page 88 Appendix JOB-List JOB no. Processes Material Diameter [mm] coldArc - Mg/Mg Ar-70 / He-30 (I3) Flux cored wire rutile FCW CrNi Rutile CO2-100 (C1) Flux cored wire rutile FCW CrNi Rutile CO2-100 (C1) Standard GMAW / pulse AlMg3 Ar-100 (I1) Standard GMAW / pulse AlMg3 Ar-100 (I1)
  • Page 89 Appendix JOB-List JOB no. Processes Material Diameter [mm] Surfacing NiCr 6625 / 2.4831 Ar-78 / He-20 / CO2-2 (M12) Surfacing NiCr 6625 / 2.4831 Ar-78 / He-20 / CO2-2 (M12) Standard GMAW / pulse CrNi 25 20 / 1.4842 Ar-97.5 / CO2-2.5 (M12) Standard GMAW / pulse CrNi 25 20 / 1.4842 Ar-97.5 / CO2-2.5 (M12)
  • Page 90 Appendix JOB-List JOB no. Processes Material Diameter [mm] coldArc / coldArc puls CrNi 19 12 3 / 1.4430 Ar-97.5 / CO2-2.5 (M12) coldArc / coldArc puls CrNi 22 9 Ar-97.5 / CO2-2.5 (M12) 3/1.4462/Duplex coldArc / coldArc puls CrNi 22 9 Ar-97.5 / CO2-2.5 (M12) 3/1.4462/Duplex coldArc / coldArc puls...

  • Page 91: Parameter Overview - Setting Ranges

    Appendix Parameter overview – setting ranges Parameter overview – setting ranges 7.2.1 MIG/MAG welding Name Display Setting range Gas pre-flow time "t1" Wire feed speed, relative (start program Start) Voltage correction Start time "t2" 0,00 - 20,0 Slope time "t3" (time from start program Start to main pro- 0,00 - 20,0 gram P...

  • Page 92: Tig Welding

    Appendix Parameter overview – setting ranges 7.2.2 TIG welding Name Display Setting range Gas pre-flow time "t1" Ignition current "t2" (percentage of main current "t4") Start time "t2" 20,0 Slope time "t3" 20,0 Main current "t4" (depending on power source) Pulse current "t4"...

  • Page 93: 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" 099-00HPXQ-EW501 07.05.2021...

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