EWM drive 4X IC HP D200 Operating Instructions Manual
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EWM drive 4X IC HP D200 Operating Instructions Manual

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Operating instructions
Wire feed unit
EN
drive 4X IC HP D200
099-005508-EW501
Observe additional system documents!
04.04.2016

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Summary of Contents for EWM drive 4X IC HP D200

  • Page 1 Operating instructions Wire feed unit drive 4X IC HP D200 099-005508-EW501 Observe additional system documents! 04.04.2016...
  • Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment.

  • Page 3: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 Safety instructions ..........................6 Notes on the use of these operating instructions ................6 Explanation of icons ........................7 General ............................8 Transport and installation ......................12 2.4.1 Ambient conditions .......................
  • Page 4 Contents Notes on the use of these operating instructions 5.8.7.1 Selecting the display unit................43 5.8.7.2 Operating point setting using material thickness .......... 43 5.8.7.3 Arc length correction setting ................44 5.8.7.4 Accessory components for operating point setting ........44 5.8.7.5 coldArc / coldArc puls ..................
  • Page 5 Resetting a single JOB ....................107 7.3.2 Resetting all JOBs ...................... 108 Vent coolant circuit ........................109 8 Technical data ............................ 110 drive 4X IC HP D200........................110 9 Accessories ............................111 General accessories ........................111 Remote control/connecting and extension cable ............... 111 9.2.1 19-pole connection .....................

  • Page 6: Safety Instructions

    Safety instructions Notes on the use of these operating instructions Safety instructions 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. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •...

  • Page 7: Explanation Of Icons

    Safety instructions Explanation of icons Explanation of icons Symbol Description Special technical points which users must observe. Correct Wrong Press Do not press Press and keep pressed Turn Switch Switch off machine Switch on machine enter the menu ENTER Navigating in the menu NAVIGATION Exit the menu EXIT...

  • Page 8: General

    Safety instructions General General DANGER Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •...
  • Page 9 Safety instructions General WARNING Risk of injury due to radiation or heat! Arc radiation results in injury to skin and eyes. Contact with hot workpieces and sparks results in burns. • Use welding shield or welding helmet with the appropriate safety level (depending on the application)! •...
  • Page 10 Safety instructions General CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
  • Page 11 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes > see 8 chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.

  • Page 12: Transport And Installation

    Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •...

  • Page 13: Ambient Conditions

    Safety instructions Transport and installation 2.4.1 Ambient conditions CAUTION Installation site! The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work.

  • Page 14: Intended Use

    Intended use Use and operation solely with the following machines Intended use WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! •...

  • Page 15: 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 The designated machine conforms to EC Directives and standards in terms of its design and construction: •...

  • Page 16: Machine Description - Quick Overview

    Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Carrying handle Slide latch, lock for the protective cap Wire spool inspection window Check wire supply Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Machine feet 19-pole connection socket (analogue)

  • Page 17: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description G¼" connecting nipple, shielding gas connection 7-pole connection socket (digital) • Control lead for wire feed unit Power source welding current connector plug Welding current connection between power source and wire feeder Quick connect coupling (red) coolant return Quick connect coupling (blue)

  • Page 18: Inside View

    Machine description – quick overview Inside view Inside view Figure 4-3 Item Symbol Description Wire spool holder Securing hook Strain relief for intermediate hose package (snap hook variant) Wire feed unit Push-button, wire inching For inching the wire electrode after changing wire spools. (The welding wire is inched through the hose package to the welding torch without any voltage or gas).

  • Page 19: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-4 Item Symbol Description Functional sequence > see 4.4.1 chapter Push-button, welding task selection (JOB) SP1/2/3 - Special JOBs (Phoenix Expert only). Pressing the push-button longer: special JOB selection.
  • Page 20 Machine description – quick overview Machine control – Operating elements Item Symbol Description Rotary knob, welding parameter setting • ---------- Setting the welding task (JOB). With machines of the Phoenix Expert series, welding tasks are selected at the power source control. •...

  • Page 21: Functional Sequence

    Machine description – quick overview Machine control – Operating elements 4.4.1 Functional sequence Figure 4-5 Item Symbol Description Select welding parameters button This button is used to select the welding parameters depending on the welding process and operating mode used. Signal light, gas pre-flow time Setting range 0.0 s to 20.0 s Signal light, start program (P...

  • Page 22: Design And Function

    Design and function General Design and function General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •...

  • Page 23: Installation

    Design and function Installation CAUTION Damage due to incorrect connection! Accessory components and the power source itself can be damaged by incorrect connection! • Only insert and lock accessory components into the relevant connection socket when the machine is switched off. •...

  • Page 24: Welding Torch Cooling System

    Design and function Welding torch cooling system Welding torch cooling system CAUTION Coolant mixtures! Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void! • Only use the coolant described in this manual (overview of coolants). •...

  • Page 25: Notes On The Installation Of Welding Current Leads

    Design and function Notes on the installation of welding current leads Notes on the installation of welding current leads Incorrectly installed welding current leads can cause faults in the arc (flickering). Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel.
  • Page 26 Design and function Notes on the installation of welding current leads Use an individual welding lead to the workpiece for each welding machine! Figure 5-2 Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops! Always keep leads as short as possible! Lay any excess cable lengths in meanders.

  • Page 27: Connecting The Intermediate Hose Package To The Power Source

    Design and function Connecting the intermediate hose package to the power source Connecting the intermediate hose package to the power source 5.5.1 Strain relief Figure 5-4 Item Symbol Description Power source Intermediate hose package G¼" connecting nipple, shielding gas connection 7-pole connection socket (digital) •...

  • Page 28: Snap Hook Strain Relief

    Design and function Connecting the intermediate hose package to the power source 5.5.2 Snap hook strain relief CAUTION Missing or incorrectly fitted strain relief! Connection sockets or connection plugs on the machine, or the intermediate tube package, may be damaged if the strain relief is missing or incorrectly fitted. The strain relief takes the strain from cables, plugs and sockets.

  • Page 29: Shielding Gas Supply (Shielding Gas Cylinder For Welding Machine)

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) Shielding gas supply (shielding gas cylinder for welding machine) 5.6.1 Gas test • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. •...

  • Page 30: Welding Data Display

    Design and function Welding data display Welding data display To the left and right of the control displays are the "Parameter selection" buttons ( ). They are used to select welding parameters to be displayed. Each press of the button advances the display to the next parameter (LEDs next to the button indicate the selection).

  • Page 31: Mig/Mag Welding

    Design and function MIG/MAG welding MIG/MAG welding 5.8.1 Welding torch connection CAUTION Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur. •...
  • Page 32 Design and function MIG/MAG welding Preparation for connecting welding torches with a liner: • Push forward the capillary tube on the wire feed side in the direction of the Euro torch connector and remove it there. • Insert the liner guide tube from the Euro torch connector side. •...
  • Page 33 Design and function MIG/MAG welding Figure 5-9 Item Symbol Description Welding torch Welding torch hose package Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Quick connect coupling (red) coolant return...

  • Page 34: Wire Feed

    Design and function MIG/MAG welding 5.8.2 Wire feed 5.8.2.1 Open the protective flap of the wire feeder CAUTION To perform the following steps, the protective flap of the wire feeder needs to be opened. Make sure to close the protective flap again before starting to work. •...

  • Page 35: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.8.2.3 Changing the wire feed rollers Figure 5-11 Item Symbol Description Tommy The tommy is used to secure the closure brackets of the wire feed rollers. Closure bracket The closure brackets are used to secure the wire feed rollers. Feed roll tensioner Fixing the clamping unit and setting the pressure.
  • Page 36 Design and function MIG/MAG welding Unsatisfactory welding results due to faulty wire feeding! The wire feed rolls must be suitable for the diameter of the wire and the material. The wire feed rolls are colour-coded to facilitate distinction (see the Wire feed roll overview table). When working with a wire diameter of >...

  • Page 37: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.8.2.4 Inching the wire electrode CAUTION Risk of injury due to moving parts! The wire feeders are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons! • Do not reach into rotating or moving parts or drive components! •...
  • Page 38 Design and function MIG/MAG welding Figure 5-12 Item Symbol Description Welding wire Wire feed nipple Guide tube Adjusting nut • Extend and lay out the torch hose package. • Carefully unwind the welding wire from the wire spool and insert through the wire feed nipples up to the wire feed rollers.

  • Page 39: Spool Brake Setting

    Design and function MIG/MAG welding 5.8.2.5 Spool brake setting Figure 5-14 Item Symbol Description Allen screw Securing the wire spool retainer and adjustment of the spool brake • Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect. Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation! 5.8.3...

  • Page 40: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.8.5 Definition of MIG/MAG welding tasks 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 shielding gas type have been predefined •...

  • Page 41: Choke Effect / Dynamics

    (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 selecting program 1 the relevant superPuls variant (depending on the material) is activated as well.

  • Page 42: Burn-Back

    Design and function MIG/MAG welding 5.8.6.5 Burn-back EXIT ENTER Figure 5-17 Display Setting/selection menu burn back Set burn back Parameter setting (setting range 0 to 499) Back-burn set too high: large drops developing on the wire electrode result in poor ignition properties or the wire electrode sticking to the welding nozzle.

  • Page 43: Mig/Mag Operating Point

    Design and function MIG/MAG welding 5.8.7 MIG/MAG operating point The operating point (welding output) is specified using the principle of MIG/MAG one-dial operation, i.e. the user need only specify the operating point by setting the required wire speed, for example, and the digital system will calculate the optimum values for welding current and voltage (operating point).

  • Page 44: Arc Length Correction Setting

    Design and function MIG/MAG welding 5.8.7.3 Arc length correction setting The arc length can be corrected as follows. Operating Action Result Display element "Arc length correction" setting (Display example: -0.9V, setting range -9.9 V to +9.9 V) 5.8.7.4 Accessory components for operating point setting The operating point can also be set with various accessory components such as •...

  • Page 45: Coldarc / Coldarc Puls

    Design and function MIG/MAG welding 5.8.7.5 coldArc / coldArc puls Heat-reduced, low-spatter short arc for high dimensional stability welding and brazing, plus root welding with excellent gap bridging capabilities. Figure 5-19 After selecting the coldArc process > see 5.8.6 chapter the following properties are available: •...

  • Page 46: Forcearc / Forcearc Puls

    Design and function MIG/MAG welding 5.8.7.6 forceArc / forceArc puls Low-heat, directionally stable and powerful high-performance arc with deep fusion penetration for the upper power range Unalloyed, low-alloy and high-alloy steels as well as high-tensile fine-grained steels. Figure 5-20 • Smaller included angle due to deep penetration and directionally stable arc •...

  • Page 47: Rootarc/Rootarc Puls

    Design and function MIG/MAG welding 5.8.7.7 rootArc/rootArc puls Short arc with perfect weld modelling capabilities for effortless gap bridging, especially for positional welding Figure 5-21 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion •...

  • Page 48: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 5.8.8 MIG/MAG functional sequences / operating modes 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). 5.8.8.1 Explanation of signs and functions Symbol Meaning Press torch trigger...
  • Page 49 Design and function MIG/MAG welding Non-latched mode 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 50 Design and function MIG/MAG welding Non-latched operation with superpulse 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 flows. •...
  • Page 51 Design and function MIG/MAG welding Special, non-latched Figure 5-25 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 Design and function MIG/MAG welding Spot welding Figure 5-26 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 53 Design and function MIG/MAG welding Special, non-latched with superpulse 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 is flowing (start program P for the time t START...
  • Page 54 Design and function MIG/MAG welding Latched mode 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 55 Design and function MIG/MAG welding Latched mode with superpulse Figure 5-29 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 56 Design and function MIG/MAG welding Latched with changing welding method (process switching) To activate or set the function > see 5.8.17 chapter. Figure 5-30 1st cycle: • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at "creep speed"...
  • Page 57 Design and function MIG/MAG welding Latched special Figure 5-31 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 58 Design and function MIG/MAG welding Special latched with changing welding method by tapping (process switching) To activate or set the function > see 5.8.17 chapter. Figure 5-32 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) •...
  • Page 59 Design and function MIG/MAG welding Special latched with changing welding method (process switching) To activate or set the function > see 5.8.17 chapter. Figure 5-33 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) •...
  • Page 60 Design and function MIG/MAG welding Special, latched with superpulse Figure 5-34 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 61: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.8.9 MIG/MAG program sequence ("Program steps" mode) Certain materials, such as aluminium, require special functions in order to be able to weld them safely and at high quality. The latched special operating mode is used here with the following programs: •...

  • Page 62: Mig/Mag Overview Of Parameters

    Design and function MIG/MAG welding 5.8.9.2 MIG/MAG overview of parameters , and P are set as relative programs ex faxtory. They relate to percentages of the START wire feed value of the main program P . These programs can also be set in an absolute manner, if desired (see Setting of special parameter P21).

  • Page 63: Example, Tack Welding (Non-Latched)

    Design and function MIG/MAG welding 5.8.9.3 Example, tack welding (non-latched) Figure 5-37 Basic parameters Parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 64: Example, Aluminium Welding (Latched Special)

    Design and function MIG/MAG welding 5.8.9.5 Example, aluminium welding (latched special) Figure 5-39 Basic parameters Welding parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20.0s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 65: Example, Visible Seams (Latched Super Pulse)

    Design and function MIG/MAG welding 5.8.9.6 Example, visible seams (latched super pulse) Figure 5-40 Basic parameters Welding parameter Meaning / explanation Setting range GASstr Gas pre-flow time 0.0s to 20.0s GASend: Gas post-flow time 0.0s to 20.0s RUECK Wire burn-back length 2 to 500 "P "...

  • Page 66: Main Program A Mode

    Design and function MIG/MAG welding 5.8.10 Main program A mode Different welding tasks or positions on a workpiece demand various welding performances (operating points) or welding programs. The following parameters are stored in each of the up to 16 programs: •...
  • Page 67 Design and function MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-41 Example 2: Welding different positions on a workpiece (latched) Figure 5-42 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-43 Up to 16 programs (P...

  • Page 68: Selecting Parameters (Program A)

    Design and function MIG/MAG welding 5.8.10.1 Selecting parameters (program A) Changes to the welding parameters can only be made when the key switch is in position "1". Operating Action Result Display element Change welding data display over to program display. (LED Prog is on) Select program number.

  • Page 69: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.8.12 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 Other functions are also possible by tapping the torch trigger, depending on the machine type and control configuration >...

  • Page 70: Switching Between Push/Pull And Intermediate Drive

    Design and function MIG/MAG welding 5.8.13.2 Switching between Push/Pull and intermediate drive DANGER 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 71: Expert Menu (Mig/Mag)

    Design and function MIG/MAG welding 5.8.14 Expert menu (MIG/MAG) The expert menu includes functions and parameters which are either not set on the machine control, or which do not require regular setting. 5.8.14.1 Selection ENTER (Enter the menu) • Keep the "welding parameters" push-button pressed for 3 s. NAVIGATION (Navigate the menu) •...
  • Page 72 Design and function MIG/MAG welding Display Setting/selection Correct wire burn-back (setting range 0–499) If too high a value is set, a large ball will form at the tip of the wire electrode (bad re- ignition) or the wire electrode sticks to the contact tip. If too low a value is set, the wire electrode sticks to the weld pool.

  • Page 73: Tig Welding

    Design and function TIG welding TIG welding 5.9.1 Welding torch connection Figure 5-46 Item Symbol Description Welding torch Welding torch hose package Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Quick connect coupling (red) coolant return Quick connect coupling (blue) coolant supply...

  • Page 74: Welding Task Selection

    Design and function TIG welding 5.9.2 Welding task selection • Select JOB 127 (TIG welding task). It is only possible to change the JOB number when no welding current is flowing. Operating Action Result Display element Select JOB number input Set the JOB number The machine adopts the required setting after approx.

  • Page 75: Function Sequences/Operating Modes

    Design and function TIG welding 5.9.5 Function sequences/operating modes 5.9.5.1 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 Special, latched...
  • Page 76 Design and function TIG welding Non-latched mode Figure 5-48 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 •...
  • Page 77 Design and function TIG welding Latched mode Figure 5-50 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 78: Tig Automatic Cut-Out

    Design and function TIG welding Latched special Figure 5-51 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 79: Tig Program Sequence ("Program Steps" Mode)

    Design and function TIG welding 5.9.7 TIG program sequence ("Program steps" mode) Figure 5-52 Basic parameters Item Meaning/explanation Setting range Gas pre-flow time 0 s to 0.9 s START 0% to 200% Ignition current Duration (start program) 0 s to 20 s Slope duration from P to P 0 s to 20 s...

  • Page 80: Mma Welding

    Design and function MMA welding 5.10 MMA welding 5.10.1 Welding task selection • Select JOB 128 (MMA welding task). It is only possible to change the JOB number when no welding current is flowing. Operating Action Result Display element Select JOB number input Set the JOB number The machine adopts the required setting after approx.

  • Page 81: Hotstart

    Design and function MMA welding 5.10.4 Hotstart The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) = Hotstart current Welding current Time Figure 5-53 For hotstart parameter settings, > see 5.10.6 chapter 5.10.5 Antistick Anti-stick prevents the electrode from annealing.

  • Page 82: Remote Control

    Design and function Remote control 5.11 Remote control CAUTION Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •...

  • Page 83: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.12.1 Remote control connection socket, 19-pole Figure 5-56 Signal form Short description Output Connection for PE cable screen Output Reference voltage for potentiometer 10 V (max. 10 mA) Input Control voltage specification (0 V–10 V) – wire feed speed Output Reference potential (0 V) Input...

  • Page 84: Access Control

    Design and function Access control 5.13 Access control To protect against unauthorised or unintentional adjustment of the welding parameters on the machine, the control input can be locked with the aid of a key switch. In key switch position 1 all functions and parameters can be set without restriction. In key switch position 0 the following functions and parameters cannot be changed: •...

  • Page 85: Selecting, Changing And Saving Parameters

    Design and function Special parameters (advanced settings) 5.14.1 Selecting, changing and saving parameters ENTER (Enter the menu) • Switch off machine at the main switch. • Press and hold the "left parameter selection" button and switch the machine on again at the same time.
  • Page 86 Design and function Special parameters (advanced settings) Display Setting/selection Enable special jobs SP1 to SP3 0 = ------- no enabling (Ex works) 1 = ------- enabling of Sp1-3 Correction operation, threshold value setting 0 = ------- correction operation switched off (Ex works) 1 = ------- correction operation on "Main program (PA)"...

  • Page 87: Reset To Factory Settings

    Design and function Special parameters (advanced settings) Display Setting/selection Predefined pulse arc welding process in the PA program 0 = -------- Predefined pulse arc welding process in the PA program is disabled. 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 88: Special Parameters In Detail

    Design and function Special parameters (advanced settings) 5.14.1.2 Special parameters in detail Ramp time for wire inching (P1) The wire inching starts with a speed 1.0 m/min for 2 secs. It is subsequently increased to a ramp function to 6.0 m/min. The ramp time can be set between two ranges. During wire inching, the speed can be changed by means of the welding parameter setting rotary dial.
  • Page 89 Design and function Special parameters (advanced settings) Correction operation, threshold value setting (P7) The correction operation is switched on and off for all JOBs and their programs at the same time. A correction operation is specified for wire speed (DV) and welding voltage correction (Ukorr) for each JOB. The correction value is saved separately for each program.
  • Page 90 Design and function Special parameters (advanced settings) Operating Action Result Display (examples) element Left Right Press button until "PROG" LED comes Left: Wire feed speed Right: Program number Press button and hold down for approx. Left: Current limit value of the wire feed speed correction Right: Current limit value of the...
  • Page 91 Design and function Special parameters (advanced settings) 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 92 Design and function 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 93 Design and function Special parameters (advanced settings) "Single or dual operation" (P10) setting If the system is fitted with two wire feeds, no further accessory components may be operated on the 7-pole connection socket (digital)! This relates to digital remote controls, robot interfaces, documentation interfaces, welding torches with digital control lead connection, etc.
  • Page 94 Design and function Special parameters (advanced settings) Creating user-defined JOB lists A consecutive memory range where accessories such as the POWERCONTROL 2 torch can be used to switch between JOBs will be created. • Set special parameter P12 to "2". •...
  • Page 95 Design and function Special parameters (advanced settings) Lower and upper limits of the remote JOB changeover process (P13, P14) The highest and lowest JOB numbers which can be selected using accessory components, such as the PowerControl 2 torch. Avoids an accidental changeover into undesirable or undefined JOBs. Hold function (P15) Hold function active (P15 = 1) •...
  • Page 96 Design and function Special parameters (advanced settings) Selecting programs with the standard torch trigger (P17) Allows you to select a program or switch a program before starting welding. You switch to the next program by tapping the torch trigger. Once the last enabled program is reached, you start again at the beginning.
  • Page 97 Design and function Special parameters (advanced settings) Predefined absolute value for relative programs (P21) Start program (P ), down-slope program (P ) and end program (P ) can be set relative to the main START program (P ) or in an absolute manner, as desired. Function active (P21 = 1) •...

  • Page 98: Machine Configuration Menu

    Design and function Machine configuration menu 5.15 Machine configuration menu 5.15.1 Selecting, changing and saving parameters ENTER (Enter the menu) • Switch off the machine at the main switch. • Press and hold the "welding parameters" or "choke effect" (drive 4X LP) push-button and switch the machine on again at the same time.
  • Page 99 Design and function Machine configuration menu Display Setting/selection Service menu Modifications to the service menu may only be carried out by authorised maintenance staff! 099-005508-EW501 04.04.2016...

  • Page 100: Aligning The Cable Resistance

    Design and function Machine configuration menu 5.15.2 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 intermediate hose package and a 3 m water-cooled welding torch.

  • Page 101: Power-Saving Mode (Standby)

    Design and function Machine configuration menu 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 102: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal DANGER Improper maintenance and testing The equipment may only be cleaned, repaired or tested by specialist, skilled persons! A skilled person is one who, due to training, knowledge and experience, is able to recognise the dangers that can occur during testing of this equipment as well as possible subsequent damage and who is able to implement the required safety procedures.

  • Page 103: Monthly Maintenance Tasks

    In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the RoHS Directive, meet the requirements of the RoHS (Directive 2011/65/EU).

  • Page 104: Rectifying Faults

    Rectifying faults Checklist for rectifying faults 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 dealer.

  • Page 105: Error Messages

    Rectifying faults Error messages Error messages A welding machine error is indicated by an error code being displayed (see table) on the display on the machine control. In the event of a machine error, the power unit is shut down. The display of possible error numbers depends on the machine version (interfaces/functions).
  • Page 106 Rectifying faults Error messages Error Category Possible cause Remedy Error 56 Mains phase failure Check mains voltages (no Pha) Error 59 Machine incompatible Check machine used > see 3.1 chapter (Unit?) Legend for categories (error reset) a) The error message will disappear once the error has been rectified. b) The error message can be reset by pressing a key button: Welding machine control Key button...

  • Page 107: Resetting Jobs (Welding Tasks) To The Factory Settings

    Rectifying faults Resetting JOBs (welding tasks) to the factory settings Resetting JOBs (welding tasks) to the factory settings All customised welding parameters that are stored will be replaced by the factory settings. With machines of the Phoenix Expert series, JOBs can be reset to the factory settings at the power source control only (refer to the relevant system documentation).

  • Page 108: Resetting All Jobs

    Rectifying faults Resetting JOBs (welding tasks) to the factory settings 7.3.2 Resetting all JOBs JOBs 1–128 and 170–256 will be reset. Custom JOBs 129–169 are maintained. RESET ENTER EXIT Figure 7-2 Display Setting/selection RESET to factory settings The RESET will be done after pressing the button. The menu will be ended when no changes are done after 3 sec.

  • Page 109: Vent Coolant Circuit

    Rectifying faults Vent coolant circuit Vent coolant circuit Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling. To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! Figure 7-3 099-005508-EW501...

  • Page 110: Technical Data

    Technical data drive 4X IC HP D200 Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! drive 4X IC HP D200 42 VAC Supply voltage 550 A Maximum welding current at 60% DC 430 A Maximum welding current at 100% DC 0.5 m/min–25 m/min...

  • Page 111: Accessories

    Accessories General accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. Mod. 842 Ar/CO2 230bar 30l Pressure regulator with manometer 394-002910-00030 HOSE BRIDGE UNI Tube bridge 092-007843-00000 Sharpener for plastic liners...

  • Page 112: Replaceable Parts

    Replaceable parts Wire feed rollers Replaceable parts CAUTION Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •...

  • Page 113: Wire Feed Rollers For Aluminium Wire

    Replaceable parts Wire feed rollers 10.1.2 Wire feed rollers for aluminium wire Type Designation Item no. AL 4R 0.8 MM/0.03 INCH Drive roll set, 37 mm, for aluminium 092-002771-00008 WHITE AL 4R 1.0 MM/0.04 INCH Drive roll set, 37 mm, for aluminium 092-002771-00010 BLUE AL 4R 1.2 MM/0.045 INCH...

  • Page 114: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List Figure 11-1 099-005508-EW501 04.04.2016...

  • Page 115: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005508-EW501 04.04.2016...

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