EWM alpha Q 330 Progress puls LP MM TKM Operating Instructions Manual
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EWM alpha Q 330 Progress puls LP MM TKM Operating Instructions Manual

EWM alpha Q 330 Progress puls LP MM TKM Operating Instructions Manual

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099-005501-EW501
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Welding machine
alpha Q 330 Progress puls LP MM TKM
23.11.2015
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Summary of Contents for EWM alpha Q 330 Progress puls LP MM TKM

  • Page 1 Operating instructions Welding machine alpha Q 330 Progress puls LP MM TKM 099-005501-EW501 23.11.2015 Register now and benefit! Jetzt Registrieren und Profitieren! www.ewm-group.com...
  • 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 5.10.3.4 Inching the wire electrode ................40 5.10.3.5 Spool brake setting ..................42 5.10.4 Definition of MIG/MAG welding tasks ................43 5.10.5 Welding task selection ....................43 5.10.5.1 Basic welding parameters ................43 5.10.5.2 Operating mode .....................
  • Page 5 Wire feed rollers for aluminium wire ................102 10.1.3 Wire feed rollers for cored wire .................. 102 10.1.4 Wire guide ........................102 11 Appendix A ............................103 11.1 JOB-List ............................. 103 12 Appendix A ............................104 12.1 Overview of EWM branches ...................... 104 099-005501-EW501 23.11.2015...

  • 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 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 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 Technical data 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 Applications 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! • The equipment must only be used in line with proper usage and by trained or expert staff! •...

  • Page 15: Documents Which Also Apply

    3.2.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.2.2 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 4-1 099-005501-EW501 23.11.2015...
  • Page 17 Machine description – quick overview Front view Item Symbol Description Transport bar Machine control- See 4.4 Machine control – Operating elements chapter Main switch, machine on/off 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Connection socket 7-pole (digital) For connecting digital accessory components (remote control, etc.).

  • Page 18: Rear View

    Machine description – quick overview Rear view Rear view Figure 4-2 099-005501-EW501 23.11.2015...
  • Page 19 Machine description – quick overview Rear view Item Symbol Description Slide latch, lock for the protective cap Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, additional stickers with information on the replacement parts and JOB lists will be located on the inside.

  • Page 20: Inside View

    Machine description – quick overview Inside view Inside view Figure 4-3 099-005501-EW501 23.11.2015...
  • Page 21 Machine description – quick overview Inside view Item Symbol Description Welding torch function changeover switch (special welding torch required) Changing over programs or JOBs Infinite adjustment of welding performance. Wire spool holder Wire feed unit 099-005501-EW501 23.11.2015...

  • Page 22: Machine Control - Operating Elements

    Machine description – quick overview Machine control – Operating elements Machine control – Operating elements Figure 4-4 Item Symbol Description Push-button, welding task selection (JOB) SP1/2/3 Special JOBs (Phoenix Expert only). Pressing the push-button longer: special JOB selection. Pressing the push-button briefly: switching between special JOBs.
  • Page 23 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 24: 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 25: 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 26: Machine Cooling

    Design and function Machine cooling Machine cooling To obtain an optimal duty cycle from the power components, the following precautions should be observed: • Ensure that the working area is adequately ventilated. • Do not obstruct the air inlets and outlets of the machine. •...

  • Page 27: 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 28 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 29: Mains Connection

    Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations! •...

  • Page 30: Welding Torch Cooling System

    Design and function Welding torch cooling system Welding torch cooling system 5.7.1 Welding torch cooling unit connection Please note the relevant documentation of the accessory components. Figure 5-5 Item Symbol Description Cooling unit 8-pole connection socket Cooling unit control lead 4-pole connection socket Cooling unit voltage supply •...

  • Page 31: 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) WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. •...

  • Page 32: Gas Test

    Design and function Shielding gas supply (shielding gas cylinder for welding machine) 5.8.1 Gas test • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. • Initiate gas test function on the machine control. •...

  • Page 33: 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 34: Mig/Mag Welding

    Design and function MIG/MAG welding 5.10 MIG/MAG welding 5.10.1 Welding torch connection On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a steel liner. Conversion is necessary if a welding torch with a liner is used! •...
  • Page 35 Design and function MIG/MAG welding Figure 5-8 Item Symbol Description Welding torch Welding torch hose package 19-pole connection socket (analogue) For connecting analogue accessory components (remote control, welding torch control lead, etc.) Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated •...

  • Page 36: Connection For Workpiece Lead

    Design and function MIG/MAG welding 5.10.2 Connection for workpiece lead Figure 5-9 Item Symbol Description Workpiece "-" welding current connection socket • MIG/MAG welding: Workpiece connection • Insert the plug on the workpiece lead into the "-" welding current connection socket and lock. 099-005501-EW501 23.11.2015...

  • Page 37: Wire Feed

    Design and function MIG/MAG welding 5.10.3 Wire feed 5.10.3.1 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 38: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.10.3.3 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 39 Design and function MIG/MAG welding Unsatisfactory welding results due to faulty wire feeding! The wire feed rollers must be suitable for the diameter of the wire and the material. The wire feed rollers are colour-coded to facilitate distinction (see the Wire feed roller overview table). Wire feed roller overview table Material Diameter...

  • Page 40: Inching The Wire Electrode

    Design and function MIG/MAG welding 5.10.3.4 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 41 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 42: Spool Brake Setting

    Design and function MIG/MAG welding 5.10.3.5 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! 099-005501-EW501...

  • Page 43: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.10.4 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 44: Operating Mode

    Design and function MIG/MAG welding 5.10.5.2 Operating mode Operating Action Result Display element Select operating mode No change The LED displays the selected operating mode. Non-latched operation Latched operation Green Special non-latched mode Red Spot operating mode Special latched mode 5.10.5.3 Choke effect / dynamics ENTER EXIT...

  • Page 45: Mig/Mag Operating Point

    Design and function MIG/MAG welding 5.10.6 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 46: Arc Length Correction Setting

    Design and function MIG/MAG welding 5.10.6.3 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) 5.10.6.4 Accessory components for operating point setting The operating point can also be set with various accessory components such as •...

  • Page 47: Coldarc / Coldarc Puls

    Design and function MIG/MAG welding 5.10.7 coldArc / coldArc puls Heat-reduced, low-spatter short arc for welding and brazing of thin metal sheets with low distortion and for root welding with excellent gap bridging properties. Figure 5-17 After selecting the coldArc process - See 5.10.5 Welding task selection chapter the following properties are available: •...

  • Page 48: Forcearc / Forcearc Puls

    Design and function MIG/MAG welding 5.10.8 forceArc / forceArc puls Heat-reduced, directionally stable and powerful arc with deep penetration for the upper power range. Figure 5-18 • Smaller included angle due to deep penetration and directionally stable arc • Excellent root and sidewall fusion •...

  • Page 49: Rootarc/Rootarc Puls

    Design and function MIG/MAG welding 5.10.9 rootArc/rootArc puls Short arc with easy weld modelling capabilities for effortless gap bridging and positional welding. Figure 5-19 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion •...

  • Page 50: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 5.10.11 MIG/MAG functional sequences / operating modes 5.10.11.1 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 Wire electrode is being conveyed Wire creep Wire burn-back Gas pre-flows...
  • Page 51 Design and function MIG/MAG welding Non-latched mode Figure 5-21 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 52 Design and function MIG/MAG welding Special, non-latched 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 is flowing (start program P for the time t START...
  • Page 53 Design and function MIG/MAG welding Spot welding Figure 5-23 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 54 Design and function MIG/MAG welding Latched mode 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 55 Design and function MIG/MAG welding Latched special 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 START Step 2...

  • Page 56: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.10.12 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 57: Example, Tack Welding (Non-Latched)

    Design and function MIG/MAG welding 5.10.12.1 Example, tack welding (non-latched) Figure 5-27 5.10.12.2 Example, aluminium tack welding (non-latched special) Figure 5-28 5.10.12.3 Example, aluminium welding (latched special) Figure 5-29 099-005501-EW501 23.11.2015...

  • Page 58: Main Program A Mode

    Design and function MIG/MAG welding 5.10.13 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 59 Design and function MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-30 Example 2: Welding different positions on a workpiece (latched) Figure 5-31 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-32 Up to 16 programs (P...

  • Page 60: Selecting Parameters (Program A)

    Design and function MIG/MAG welding 5.10.13.1 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 61: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.10.15 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- See 5.17.1.2 Special parameters in detail chapter: •...

  • Page 62: Tig Welding

    Design and function TIG welding 5.11 TIG welding 5.11.1 Welding torch and workpiece line connection Figure 5-34 Item Symbol Description Welding torch Welding torch hose package "-" welding current connection socket • TIG welding: Welding current connection for welding torch Welding torch connection (Euro or Dinse torch connector) Welding current, shielding gas and torch trigger integrated Workpiece...

  • Page 63: Welding Task Selection

    Design and function TIG welding 5.11.2 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 64: Function Sequences/Operating Modes

    Design and function TIG welding 5.11.4 Function sequences/operating modes 5.11.4.1 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 65 Design and function TIG welding Non-latched mode Figure 5-36 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 66 Design and function TIG welding Latched mode Figure 5-38 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 67: Tig Automatic Cut-Out

    Design and function TIG welding Latched special Figure 5-39 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 68: Mma Welding

    Design and function MMA welding 5.12 MMA welding CAUTION Risk of being crushed or burnt. When replacing spent or new stick electrodes • Switch off machine at the main switch • Wear appropriate safety gloves • Use insulated tongs to remove spent stick electrodes or to move welded workpieces and •...

  • Page 69: Welding Task Selection

    Design and function MMA welding 5.12.2 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 70: Protecting Welding Parameters From Unauthorised Access

    Design and function Protecting welding parameters from unauthorised access 5.13 Protecting welding parameters from unauthorised access 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.

  • Page 71: Automation Interface

    Design and function Interfaces for automation 5.15.1 Automation interface Input / Description Diagram output Output Connection for cable shielding Output IGRO Current flows signal I>0 (maximum load 20 (open mA / 15 V) collector) 0 V = welding current flows Input Not/Aus Emergency stop for higher level shut-down of the power source.

  • Page 72: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.15.2 Remote control connection socket, 19-pole Figure 5-43 Signal form Short description Output Connection for PE cable screen Output Reference voltage for potentiometer 10 V (max. 10 mA) Control voltage specification (0 V–10 V) – wire feed speed Input Output Reference potential (0 V)

  • Page 73: Rint X12 Robot Interface

    Design and function Interfaces for automation 5.15.3 RINT X12 robot interface The standard digital interface for mechanised applications
 (optional, retrofitting on the machine or external fitting by the customer) Functions and signals: • Digital inputs: start/stop, operating modes, JOB and program selection, inching, gas test •...

  • Page 74: Pc Interfaces

    Design and function PC Interfaces 5.16 PC Interfaces CAUTION Equipment damage or faults may occur if the PC is connected incorrectly! Not using the SECINT X10USB interface results in equipment damage or faults in signal transmission. The PC may be destroyed due to high frequency ignition pulses. •...

  • Page 75: Selecting, Changing And Saving Parameters

    Design and function Special parameters (advanced settings) 5.17.1 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 76 Design and function Special parameters (advanced settings) Display Setting/selection Ramp time for wire inching 0 = normal inching (10s ramp time) 1 = fast inching (3s ramp time) (Ex works) Block program "0" 0 = P0 enabled (Ex works) 1 = P0 blocked Display mode for Up/Down welding torch with one-digit 7-segment display (two keys) 0 = normal display (ex works)

  • Page 77: Reset To Factory Settings

    Design and function Special parameters (advanced settings) Display Setting/selection Block JOB mode 0 = Block JOB mode not enabled (Ex works) 1 = Block JOB mode enabled Program selection with standard torch trigger 0 = no program selection (Ex works) 1 = program selection possible Mean value display for superPuls Function switched off.

  • Page 78: Special Parameters In Detail

    Design and function Special parameters (advanced settings) 5.17.1.2 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 79 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 80 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 81 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 82 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 83 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 84 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 85 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 86: Machine Configuration Menu

    Design and function Machine configuration menu 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 87 Design and function Machine configuration menu switch the machine on again at the same time. NAVIGATION (Navigate the menu) • Select parameters by turning the "welding parameter setting" rotary knob. • Set or change parameters by turning the "arc length correction/select welding program" rotary knob.

  • Page 88: Aligning The Cable Resistance

    Design and function Machine configuration menu 5.18.2 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 89: 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 90: 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 91: 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 92: 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 93: 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 94 Rectifying faults Error messages Error Category Possible cause Remedy Error 56 Mains phase failure Check mains voltages (no Pha) 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 RC1 / RC2...

  • Page 95: 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. 7.3.1 Resetting a single JOB RESET ENTER EXIT Figure 7-1 Display Setting/selection...

  • Page 96: Resetting All Jobs

    Rectifying faults General operating problems 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 97: 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 7-3 099-005501-EW501...

  • Page 98: Technical Data

    Technical data alpha Q 330 Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! alpha Q 330 MIG/MAG Setting range for welding current 5 A–330 A Setting range for welding voltage 14.3 V–30.5 V 20.2 V–33.2 V 10.2 V–23.2 V Duty cycle at 40 °C / 40%...

  • Page 99: 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. Cool71 U42 Air cooling unit, heavy-duty pump and enhanced 090-008201-00502 cooling cool71 U43 Cooling unit with centrif.

  • Page 100: Remote Control/Connecting And Extension Cable

    Accessories Remote control/connecting and extension cable Remote control/connecting and extension cable 9.4.1 7-pole connection Type Designation Item no. R40 7POL Remote control, 10 programs 090-008088-00000 R50 7POL Remote control, all welding machine functions can 090-008776-00000 be set directly at the workplace FRV 7POL 0.5 m Extension/connecting cable 092-000201-00004...

  • Page 101: 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 102: 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 103: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List Figure 11-1 099-005501-EW501 23.11.2015...

  • Page 104: Overview Of Ewm Branches

    Appendix A Overview of EWM branches Appendix A 12.1 Overview of EWM branches 099-005501-EW501 23.11.2015...

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