EWM alpha Q Progress drive 4D EF Operating Instructions Manual
  1. Manuals
  2. Brands
  3. EWM Manuals
  4. Wire Feeders
  5. alpha Q Progress drive 4D EF
  6. Operating instructions manual
EWM alpha Q Progress drive 4D EF Operating Instructions Manual

EWM alpha Q Progress drive 4D EF Operating Instructions Manual

Wire feed unit
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operating instructions
Wire feed unit
EN
alpha Q Progress drive 4D EF
099-005459-EW501
Observe additional system documents!
17.12.2015

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the alpha Q Progress drive 4D EF and is the answer not in the manual?

Questions and answers

Related Manuals for EWM alpha Q Progress drive 4D EF

Summary of Contents for EWM alpha Q Progress drive 4D EF

  • Page 1 Operating instructions Wire feed unit alpha Q Progress drive 4D EF 099-005459-EW501 Observe additional system documents! 17.12.2015...
  • 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 5.8.6.1 Selecting the display unit................46 5.8.6.2 Operating point setting using material thickness .......... 46 5.8.6.3 Arc length correction setting ................47 5.8.6.4 Accessory components for operating point setting ........47 5.8.7 coldArc / coldArc puls ....................
  • Page 5 Wire feed rollers for aluminium wire ................117 10.1.3 Wire feed rollers for cored wire .................. 117 10.1.4 Wire guide ........................117 11 Appendix A ............................118 11.1 JOB-List ............................. 118 12 Appendix B ............................119 12.1 Overview of EWM branches ...................... 119 099-005459-EW501 17.12.2015...

  • 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 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 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 Use and operation solely with the following machines Intended use Wire feeder to feed wire electrodes for gas-shielded metal-arc welding. WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly.

  • 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 4-1 099-005459-EW501 17.12.2015...
  • Page 17 Machine description – quick overview Front view Item Symbol Description Carrying handle 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. Griffmulde zum Öffnen der Schutzklappe Key switch for protection against unauthorised use Position “1”...

  • Page 18: Right Side

    Machine description – quick overview Right side Right side Figure 4-2 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 Connecting nipple G¼, shielding gas connection Wire feed unit 099-005459-EW501 17.12.2015...

  • Page 19: Left Side

    Machine description – quick overview Left side Left side Figure 4-3 Item Symbol Description Wire spool holder Welding torch function changeover switch (special welding torch required) Changing over programs or JOBs Infinite adjustment of welding performance. Wire feed unit Quick connect coupling (red) coolant return Intermediate hose package strain relief Connector plug, welding current "+"...

  • Page 20: 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 Functional sequence chapter Key button JOB-List Selection of the welding task (JOB) from the JOB list Display, left Welding current, material thickness, wire speed, hold values Push-button, parameter selection left/power-saving mode...
  • Page 21 Machine description – quick overview Machine control – Operating elements Item Symbol Description Select operating mode button Non-latched Latched Signal light lights up in green: Special non-latched Signal light lights up in red: MIG spot welding Special latched Welding type push-button Standard arc welding Pulsed arc welding Push-button, throttling effect (arc dynamics)

  • Page 22: 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 23: 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 24: 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 25 Design and function Installation CAUTION Risk of falling! If the double wire feed unit is not positioned correctly on the holder, it may fall, become damaged and cause injury to persons as a result. • Always position the inner feet of the wire feed unit in the provided recesses! •...

  • Page 26: 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 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 5-3 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: Intermediate Hose Package Connection

    Design and function Intermediate hose package connection Intermediate hose package connection CAUTION Hazards due to electrical current! If two wire feed units are used in turn and both units remain connected to the machine, open circuit or welding voltage is present in all lines. •...
  • Page 30 Design and function Intermediate hose package connection Item Symbol Description Power source Intermediate hose package G¼" connecting nipple, shielding gas connection Shielding gas supply to the central connection of the second welding torch Connector plug, welding current "+" Welding current connection on wire feed unit Quick connect coupling (red) coolant return Quick connect coupling (blue)

  • 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) 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 32: 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 33: 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 34 Design and function MIG/MAG welding Figure 5-7 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 Quick connect coupling (red) coolant return...

  • Page 35: 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 36: Changing The Wire Feed Rollers

    Design and function MIG/MAG welding 5.8.2.3 Changing the wire feed rollers Figure 5-9 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 37 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 38: 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 39 Design and function MIG/MAG welding Depending on the design of the machine, the design of the wire feed may be the reverse of that shown! Figure 5-10 Item Symbol Description Welding wire Wire feed nipple Guide tube Adjusting nut • Extend and lay out the torch hose package.

  • Page 40: Spool Brake Setting

    Design and function MIG/MAG welding • The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll tensioner setting nuts depending on the welding consumable used. A table with the setting values can be found on a sticker near the wire drive. Version 1: left hand mounting Version 2: right hand mounting Figure 5-11...

  • Page 41: Basic Settings For Operation With Two Wire Feed Units

    Design and function MIG/MAG welding 5.8.3 Basic settings for operation with two wire feed units The wire feeder controls are configured ex works for double wire feeder operation. This setting should be checked and corrected, if necessary, should the controls have been reset to the factory settings or in the event of errors.

  • Page 42: Switching Between Wire Feed Units

    Design and function MIG/MAG welding Please note! • The system is not designed for simultaneous welding. • Do not connect any further accessories to the 7-pole connection socket. 5.8.3.1 Switching between wire feed units On the welding torch of the inactive wire feed •...

  • Page 43: Definition Of Mig/Mag Welding Tasks

    Design and function MIG/MAG welding 5.8.4 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: Choke Effect / Dynamics

    EWM welding processes offers many possibilities. Welding performance can be represented as average value (ex works) or solely as program A value. If the average value display is activated the signal lights of the main (PA) and reduced main program (PB) are illuminated simultaneously.

  • Page 45: Burn-Back

    Design and function MIG/MAG welding 5.8.5.6 Burn-back EXIT ENTER Figure 5-15 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 46: Mig/Mag Operating Point

    Design and function MIG/MAG welding 5.8.6 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 47: Arc Length Correction Setting

    Design and function MIG/MAG welding 5.8.6.3 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) 5.8.6.4 Accessory components for operating point setting The operating point can also be set with various accessory components such as •...

  • Page 48: Coldarc / Coldarc Puls

    Design and function MIG/MAG welding 5.8.7 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 5.8.5 Welding task selection chapter the following properties are available: •...

  • Page 49: Forcearc / Forcearc Puls

    Design and function MIG/MAG welding 5.8.8 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 50: Rootarc/Rootarc Puls

    Design and function MIG/MAG welding 5.8.9 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 51: Mig/Mag Functional Sequences / Operating Modes

    Design and function MIG/MAG welding 5.8.10 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). 5.8.10.1 Explanation of signs and functions Symbol Meaning Press torch trigger...
  • Page 52 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 53 Design and function MIG/MAG welding Non-latched operation with superpulse Figure 5-22 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 54 Design and function MIG/MAG welding Special, non-latched 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 is flowing (start program P for the time t START...
  • Page 55 Design and function MIG/MAG welding Spot welding Figure 5-24 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 56 Design and function MIG/MAG welding Special, non-latched with superpulse 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 57 Design and function MIG/MAG welding Latched mode Figure 5-26 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire feed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 58 Design and function MIG/MAG welding Latched mode 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 flows. •...
  • Page 59 Design and function MIG/MAG welding Latched with changing welding method (process switching) To activate or set the function - See 5.8.17 Expert menu (MIG/MAG) chapter. Figure 5-28 1st cycle: • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) •...
  • Page 60 Design and function MIG/MAG welding Latched special 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 is flowing (start program P START Step 2...
  • Page 61 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 Expert menu (MIG/MAG) chapter. Figure 5-30 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) •...
  • Page 62 Design and function MIG/MAG welding Special latched with changing welding method (process switching) To activate or set the function - See 5.8.17 Expert menu (MIG/MAG) chapter. Figure 5-31 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) •...
  • Page 63 Design and function MIG/MAG welding Special, latched with superpulse Figure 5-32 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 64: Mig/Mag Program Sequence ("Program Steps" Mode)

    Design and function MIG/MAG welding 5.8.11 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 65: Mig/Mag Overview Of Parameters

    Design and function MIG/MAG welding 5.8.11.2 MIG/MAG overview of parameters , and P are set as relative programs ex faxtory. They relate to percentages of the wire START 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 66: Example, Tack Welding (Non-Latched)

    Design and function MIG/MAG welding 5.8.11.3 Example, tack welding (non-latched) Figure 5-35 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 67: Example, Aluminium Welding (Latched Special)

    Design and function MIG/MAG welding 5.8.11.5 Example, aluminium welding (latched special) Figure 5-37 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 68: Example, Visible Seams (Latched Super Pulse)

    Design and function MIG/MAG welding 5.8.11.6 Example, visible seams (latched super pulse) Figure 5-38 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 69: Conventional Mig/Mag Welding (Gmaw Non Synergic)

    Design and function MIG/MAG welding 5.8.12 Conventional MIG/MAG Welding (GMAW non synergic) • With wire-feed speeds less than 8 m/min select JOB 188. • With wire-feed speeds over 8 m/min select JOB 187. You can only change the JOB number when no welding current is flowing. Operating Action Result...

  • Page 70: Main Program A Mode

    Design and function MIG/MAG welding 5.8.13 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 71 Design and function MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-39 Example 2: Welding different positions on a workpiece (latched) Figure 5-40 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-41 Up to 16 programs (P...

  • Page 72: Selecting Parameters (Program A)

    Design and function MIG/MAG welding 5.8.13.1 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 73: Standard Mig/Mag Torch

    Design and function MIG/MAG welding 5.8.15 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 5.14.1.2 Special parameters in detail chapter: •...

  • Page 74: Switching Between Push/Pull And Intermediate Drive

    Design and function MIG/MAG welding 5.8.16.2 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 75: Expert Menu (Mig/Mag)

    Design and function MIG/MAG welding 5.8.17 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. 5.8.17.1 Selection ENTER (Enter the menu) • Keep the "welding parameters" push-button pressed for 3 s. NAVIGATION (Navigate the menu) •...
  • Page 76 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 77: Tig Welding

    Design and function TIG welding TIG welding 5.9.1 Welding torch connection TIG welding torches to be connected to a Euro torch connector are available in two versions: • TIG combi welding torches are connected to the Euro torch connector of the wire feeder and to the (-) welding current plug of the power source.

  • Page 78: Welding Task Selection

    Design and function TIG welding • Insert the central plug for the welding torch into the central connector and screw together with crown nut. • Insert the welding current plug of the combi welding torch into the (-) welding current connection socket and lock into place by turning to the right (only in case of a separate welding current connection).

  • Page 79: Function Sequences/Operating Modes

    Design and function TIG welding 5.9.4 Function sequences/operating modes 5.9.4.1 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 80 Design and function TIG welding Non-latched mode Figure 5-46 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 81 Design and function TIG welding Latched mode Figure 5-48 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 82: Tig Automatic Cut-Out

    Design and function TIG welding Latched special Figure 5-49 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 83: Tig Program Sequence ("Program Steps" Mode)

    Design and function TIG welding 5.9.5 TIG program sequence ("Program steps" mode) Figure 5-50 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 84: Mma Welding

    Design and function MMA welding 5.10 MMA welding 5.10.1 Welding task selection Manual arc welding or, for short, MMA welding. It is characterised by the fact that the arc burns between a melting electrode and the molten pool. There is no external protection; any protection against the atmosphere comes from the electrode.

  • Page 85: Hotstart

    Design and function MMA welding 5.10.1.3 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 5-51 For hotstart parameter settings, - See 5.10.1.5 Parameter overview chapter 5.10.1.4 Antistick Anti-stick prevents the electrode from annealing.

  • Page 86: Air Arc Gouging

    Design and function MMA welding 5.10.2 Air arc gouging During gouging, an arc burns between a carbon electrode and the workpiece, heating the workpiece until it is molten. At the same time, the molten metal is blown out with compressed air. Special electrode holders with a compressed-air connection and carbon electrodes are required for gouging.

  • Page 87: 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 88: Remote Control Connection Socket, 19-Pole

    Design and function Interfaces for automation 5.12.1 Remote control connection socket, 19-pole Figure 5-54 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 89: 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 90: 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 91 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 92: 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 Switching the operating mode and welding type using the wire feed control 0 = Switching the operating mode and welding type using the wire feed control and...

  • Page 93: 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 94 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 95 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 96 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 97 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 98 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 99 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 100 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 101 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 102 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 103: 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 104: Aligning The Cable Resistance

    Design and function Machine configuration menu 5.15.2 Aligning the cable resistance The resistance value of the cables can be set directly or be balanced by the power source. In the delivery status the cable resistance of the power source is set to 8 mOhm. This value corresponds to a grounding cable of 5 m, an intermediate hose package of 1.5 m and a water-cooled welding torch of 3 m.

  • Page 105: Power-Saving Mode (Standby)

    Design and function Machine configuration menu 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle of the welding torch. • Cut off the welding wire to be flush with the contact tip. • Retract the welding wire a bit (approx. 50 mm) on the wire feeder. Now there should be no more welding wire in the contact tip.

  • Page 106: 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 107: 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 108: 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 109: 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 110 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 111: 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 JOB- JOB- LIST LIST...

  • Page 112: 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 JOB- JOB- LIST LIST 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 113: 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 7-3 099-005459-EW501...

  • Page 114: Technical Data

    Technical data alpha Q drive 4D Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! alpha Q drive 4D Supply voltage 42 VAC Maximum welding current at 60% DC 550 A Maximum welding current at 100% DC 430 A Wire feed speed 0.5 m/min.

  • Page 115: 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. DMDIN TN 200B AR/MIX 35L Manometer pressure regulator 094-000009-00000 AK300 Wire spool adapter K300 094-001803-00001 HOSE BRIDGE UNI Tube bridge...

  • Page 116: 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 117: 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 118: Job-List

    Appendix A JOB-List Appendix A 11.1 JOB-List Figure 11-1 099-005459-EW501 17.12.2015...

  • Page 119: Overview Of Ewm Branches

    Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005459-EW501 17.12.2015...

Table of Contents