EWM T5.01-DC Comfort 3.0 Operating Instructions Manual
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EWM T5.01-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!
1.8.2022

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Summary of Contents for EWM T5.01-DC Comfort 3.0

  • Page 1 Operating instructions Control T5.01 - DC Comfort 3.0 099-00T501-EW501 Observe additional system documents! 1.8.2022...
  • Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted.

  • Page 3: Table Of Contents

    Contents Notes on using these operating instructions Contents 1 Contents ............................3 2 For your safety ..........................5 Notes on using these operating instructions ................5 Explanation of icons ....................... 6 Safety instructions ........................7 Transport and installation ....................10 3 Intended use ..........................
  • Page 4 Contents Notes on using these operating instructions 5.1.11 Welding torch (operating variants) ................ 38 5.1.11.1 Welding torch mode ................38 5.1.11.2 Tapping function (tap torch trigger) ............41 5.1.11.3 Up/down speed ..................41 5.1.11.4 Current jump ..................41 5.1.12 RTF 1 foot-operated remote control ..............42 5.1.12.1 Start ramp ....................

  • Page 5: For Your Safety

    For your safety Notes on using these operating instructions For your safety Notes on using these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •...

  • Page 6: Explanation Of Icons

    For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the 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 –...

  • Page 7: Safety Instructions

    For your safety Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •...
  • Page 8 For your safety Safety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
  • Page 9 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...

  • Page 10: Transport And Installation

    For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the in- troduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines.
  • Page 11 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.

  • Page 12: Intended Use

    Intended use 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 13: Documents Which Also Apply

    3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the decla- ration.

  • Page 14: Part Of The Complete Documentation

    Intended use Documents which also apply 3.3.6 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 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 System push-button • ---------- Quick access to various device configuration parameters. For the complete parameter list, see the machine configuration menu > see 5.9 chapter •...
  • Page 17 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 18: 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 19 Machine control – Operating elements Overview of control sections Item Symbol Description Signal light Status display Hold 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 20: 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 Gas pre-flow time signal light Signal light for ignition optimisation (TIG) Signal light for welding task (JOB)

  • Page 21: Machine Display

    Machine control – Operating elements Machine display Item Symbol Description Signal light for secondary current 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 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 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 23: 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 24: 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 25: 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 26: 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 27: 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 5.9 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 28: 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 29: 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 30: Non-Latched Mode

    Functional characteristics TIG welding 5.1.7.2 Non-latched mode Sequence Figure 5-8 1st cycle: • Press torch trigger 1 and hold down. • Gas pre-flow time elapses. • HF ignition pulses jump from the electrode to the workpiece. The arc ignites. • The welding current flows and immediately assumes the value of the start current •...

  • Page 31: Latched Mode

    Functional characteristics TIG welding 5.1.7.3 Latched mode Sequence Figure 5-9 1st cycle • Press torch trigger 1 , the gas pre-flow time elapses. • HF start pulses jump from the electrode to the workpiece. The arc ignites. • Welding current flows and immediately assumes the set start current (search arc at minimum set- ting).

  • Page 32: Spotarc

    Functional characteristics TIG welding 5.1.7.4 spotArc This process is suitable for tack welding or joint welding of metal sheets made from steel and CrNi alloys up to a thickness of approximately 2.5 mm. Metal sheets of different thicknesses can also be welded on top of one another.

  • Page 33: 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 34: 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 5.9 chapter. Up-slope and down-slope times possible for long spot time setting range (0.01–20.0 s) only.

  • Page 35: 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 36: 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 37: 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 38: 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 5.9 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 39 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 BRT 2 Secondary current (in latched operation) BRT 1 Welding current On / Off BRT 1 Increase welding current (up/down speed) BRT 2...
  • Page 40 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 BRT 2 Increase welding current (up/down speed) Decrease welding current (up/down speed) DOWN Welding current On / Off BRT 1...

  • Page 41: 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 BRT 2 Increase program number Decrease program number DOWN Switching between program and JOB BRT 2 Increase JOB number Decrease JOB number DOWN Gas test...

  • Page 42: Rtf 1 Foot-Operated Remote Control

    Functional characteristics TIG welding 5.1.12 RTF 1 foot-operated remote control 5.1.12.1 Start ramp The start ramp function prevents an energy input that is too fast or too high immediately after the start of welding when the user depresses the pedal of the remote control too fast and too far. Example: The user sets the main current at the welding machine to 200 A.

  • Page 43: Responsiveness

    Functional characteristics TIG welding 5.1.12.2 Responsiveness This function controls the responsiveness of the welding current during the main current phase. The user can choose between linear and logarithmic responsiveness. The logarithmic setting is particularly suitable for welding with low current, e.g., for thin panels as the logarithmic responsiveness enables better control of the welding current.
  • Page 44 Functional characteristics TIG welding Display Setting/selection Slope time (secondary current to main current) Parameter activArc > see 5.1.8 chapter Setting the intensity Pulse shape ------- hard rectangular current curve and high arc force that however generates a lou- der arc noise (factory setting) ------- rectangular current curve with rounded edges and low noise.

  • Page 45: Aligning The Cable Resistance

    Functional characteristics TIG welding 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 46 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 47: 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 5.6 chapter. The following welding task selection is an example of use. In general, the selection process always has the same sequence.

  • Page 48: 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 5-33...

  • Page 49: Pulse Welding

    Functional characteristics JOB favourites 5.2.6 Pulse welding 5.2.7 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 50: Saving Current Settings To Favourites

    Functional characteristics JOB favourites 5.3.1 Saving current settings to Favourites Figure 5-37 • Press and hold the favourite memory push-button for 2 s (the signal light of the favourite status is green). 5.3.2 Loading saved Favourites Figure 5-38 • Press the favourite memory push-button (the signal light of the favourite status is green). 5.3.3 Deleting saved Favourites Figure 5-39...

  • Page 51: Managing Welding Tasks (Job Manager)

    Functional characteristics Managing welding tasks (JOB manager) Managing welding tasks (JOB manager) 5.4.1 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 5-40 5.4.2 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 52: 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 53: Machine Configuration Menu

    Functional characteristics Machine configuration menu Machine configuration menu Basic machine settings are defined in the machine configuration menu. 5.9.1 Selecting, changing and saving parameters Figure 5-42 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 54 Functional characteristics Machine configuration menu Display Setting/selection TIG HF start (soft/hard) switching ------- soft ignition (factory setting). ------- hard ignition. Ignition pulse dynamics ------- Function enabled (factory setting) ------- Function disabled Minimum current limit (TIG) > see 5.1.2 chapter Depending on the set tungsten electrode diameter ------- Function disabled ------- Function enabled (ex works) Time-based power-saving mode >...
  • Page 55 Functional characteristics Machine configuration menu Display Setting/selection spotmatic operating mode > see 5.1.7.5 chapter Ignition by contact with the workpiece -------Function enabled (ex works) -------Function disabled Spot time setting > see 5.1.7.5 chapter -------Short spot time, setting range 5 ms to 999 ms, increments of 1 ms (ex works) -------Long spot time, setting range 0.01 s to 20.0 s, increments of 10 ms (ex works) Process activation setting >...
  • Page 56 Functional characteristics Machine configuration menu Display Setting/selection Start ramp > see 5.1.12.1 chapter ------- The welding current ramps up to the preset main current (factory setting) ------- The welding current jumps immediately to the preset main current Responsiveness > see 5.1.12.2 chapter ------- Linear responsiveness ------- Logarithmic responsiveness (factory setting) Minimum current limit (AC)
  • Page 57 Functional characteristics Machine configuration menu Display Setting/selection Automated/Manual (rC on/off) operating mode Select machine/function control ------with external control voltages/signals ------with machine control Operating mode switching via interface for automated welding ------Non-latched -------Special non-latched Error output (relay) Potential-free relay contact ------Relay contact for error message is open (factory setting) ------Relay contact for error message is closed Setting for pulse pause current I2 The pulse pause current (I2) is set either relative or absolute to the main current (I1).
  • Page 58 Functional characteristics Machine configuration menu Display Setting/selection Error output to interface for automated welding, contact SYN_A ------- AC synchronisation or hot wire (ex works) ------- Error signal, negative logic ------- Error signal, positive logic ------- AVC (Arc voltage control) connection Fast take-over of control voltage (automation) ------- Function enabled ------- Function disabled (ex works)

  • Page 59: 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 60: 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 61: 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 62 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 63: 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 64 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 65 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 66 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 67 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 68 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 69: 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 70: 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 71: 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 72: Global Parameters

    Appendix Global parameters 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 Welding torch cooling, flow error limit (imperial)

  • Page 73: 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 1.8.2022...

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