EWM M3.7X-O Operating Instructions Manual
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EWM M3.7X-O Operating Instructions Manual

EWM M3.7X-O Operating Instructions Manual

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Operating instructions
Control
LP-XQ (M3.7X-N)
EN
LP-XQ (M3.7X-O)
099-5TLPXQ-EW501
Observe additional system documents!
15.12.2022

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Summary of Contents for EWM M3.7X-O

  • Page 1 Operating instructions Control LP-XQ (M3.7X-N) LP-XQ (M3.7X-O) 099-5TLPXQ-EW501 Observe additional system documents! 15.12.2022...
  • Page 2 +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other f orm of liability, regardless of type, shall be accepted.

  • Page 3: Table Of Contents

    Contents Notes on using these operating instructions Contents 1 Contents........................3 2 For your safety......................6 Notes on using these operating instructions ............... 6 Explanation of icons ....................7 Saf ety instructions ....................8 Transport and installation ..................11 3 Intended use ........................13 Use and operation solely with the following machines ..........13 Documents which also apply ...................13 Software version ....................13...
  • Page 4 Contents Notes on using these operating instructions 5.2.16.2 Switching between Push/Pull and intermediate drive......46 TIG welding......................46 5.3.1 Welding task selection ................46 5.3.1.1 Welding current setting..............46 5.3.2 Arc ignition .....................47 5.3.2.1 Lif tarc ..................47 5.3.3 Operating modes (f unctional sequences).............48 5.3.3.1 Explanation of signs and functions ..........48 5.3.3.2 Automatic cut-out ...............48...
  • Page 5 Contents Notes on using these operating instructions 6 Maintenance, care and disposal ..................68 General .......................68 Disposing of equipment..................69 7 Rectifying faults ......................70 Software version of the machine control ..............70 Error messages (power source)................70 Warnings ......................76 Resetting JOBs (welding tasks) to the factory settings ..........78 7.4.1 Resetting a single JOB ................78 7.4.2...

  • Page 6: For Your Safety

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

  • Page 7: Explanation Of Icons

    For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release / Tap / Tip user must observe. Switch off machine Release Switch on machine Press and hold Incorrect / Invalid Switch Correct / Valid Turn...

  • Page 8: Safety Instructions

    For your safety Saf ety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Caref ully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •...
  • Page 9 For your safety Saf ety instructions WARNING Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be avoided. The user has to be equipped with the complete personal protective equipment at all times.
  • Page 10 For your safety Saf ety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! •...

  • Page 11: Transport And Installation

    For your safety Transport and installation CAUTION Obligations of the operator! The respective national directives and laws must be complied with when operating the machine! • Implementation of national legislation relating to framework directive 89/391/EEC on the int- roduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines.
  • Page 12 For your safety Transport and installation CAUTION Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause risks, e.g. by causing connected machines to tip over and injure persons! • Disconnect all supply lines before transport! Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up.

  • Page 13: Intended Use

    • Do not improperly modify or convert the equipment! Use and operation solely with the following machines This description may only be used for machines with machine control M3.7X-N or M3.7X-O. Documents which also apply • Operating instructions for the connected welding machines •...

  • Page 14: Part Of The Complete Documentation

    Intended use Part of the complete documentation Part of the complete documentation This document is part of the complete documentation and valid only in combination with all other parts of these instructions! Read and observe the operating instructions for all system components, especially the safety instructions! The illustration shows a general example of a welding system.

  • Page 15: Machine Control - Operating Elements

    Machine control – Operating elements Overview of control sections Machine control – Operating elements Overview of control sections For description purposes, the machine control has been divided into two sections (A, B) to ensure maximum clarity. The setting ranges for the parameter values are summarised in the parameter overview section >...

  • Page 16: Control Section A

    Machine control – Operating elements Overview of control sections 4.1.1 Control section A Figure 4-2 099-5TLPXQ-EW501 15.12.2022...
  • Page 17 Machine control – Operating elements Overview of control sections Item Symbol Description Welding task push-button (JOB) • ----------- Pressing the pushbutton briefly: Fast switching of the available welding proce- dures in the selected basic parameters (material/wire/gas). • ----------- Pressing the pushbutton longer: Select the welding task (JOB) from the welding task list (JOB-LIST) >...

  • Page 18: Control Section B

    Machine control – Operating elements Overview of control sections 4.1.2 Control section B Figure 4-3 Item Symbol Description Display left / Lock function push-button Switching the device display between various welding parameters. Signal lamps show the selected parameter. --------- Press f or 3 s to put the machine into lock function > see 4.3.4 chapter. Wire feed speed unit signal light m/min --- Parameter value is displayed in meters per minute.
  • Page 19 Machine control – Operating elements Overview of control sections Item Symbol Description Motor current signal light During wire inching, the current motor current (wire feed mechanism) is displayed in amperes. Display right - Primary display of welding voltage This display shows the welding voltage, arc length correction, programs or welding power (switching by Display right push-button).

  • Page 20: Welding Data Display

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

  • Page 21: Operating The Machine Control

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

  • Page 22: Job Favourites

    Machine control – Operating elements Operating the machine control 4.3.5 JOB favourites Favourites are additional locations for storing and loading frequently used welding tasks, programs and their settings. The status of the Favourites (loaded, changed, not loaded) is indicated by signal lights. •...

  • Page 23: Deleting Saved Favourites

    Machine control – Operating elements Operating the machine control 4.3.5.3 Deleting saved Favourites Figure 4-8 • Press and hold the favourite memory push-button. Af ter 2 seconds, the signal light of the favourite status turns green af ter another 5 s, the signal light starts flashing red af ter another 5 s the signal light goes out •...

  • Page 24: Functional Characteristics

    Functional characteristics Shielding gas supply (shielding gas cylinder for welding machine) Functional characteristics Shielding gas supply (shielding gas cylinder for welding machine) 5.1.1 Shielding gas volume settings If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause pores to form.

  • Page 25: Purge Hose Package

    Functional characteristics MIG/MAG welding 5.1.1.2 Purge hose package 300s Figure 5-2 MIG/MAG welding 5.2.1 Wire inching The wire inching f unction is used for potential- and gas-free inching of the wire electrode after the wire spool change. By pressing and holding the wire inching button for a long time, the wire inching speed in- creases in a ramp function (special parameter P1 >...

  • Page 26: Wire Return

    Functional characteristics MIG/MAG welding 5.2.2 Wire return The wire return f unction is used to retract the wire electrode without tension and protection gas. By simul- taneously pressing and holding the wire inching and gas test buttons, the wire return speed increases in a ramp f unction (special parameter P1 >...

  • Page 27: Welding Task Selection

    Functional characteristics MIG/MAG welding 5.2.3 Welding task selection The f ollowing steps have to be carried out to select the welding job: • Select basic parameters (material type, wire diameter and shielding gas type) and welding procedures (select and enter JOB number by means of JOB-List > see 8.1 chapter). •...

  • Page 28: Welding Procedure

    Functional characteristics MIG/MAG welding 5.2.4 Welding procedure Af ter setting the basic parameters you can switch between the welding procedures MIG/MAG, forceArc, wiredArc, rootArc und coldArc (if there is a corresponding combination of the basic parameters). The pro- cess change will also change the JOB number, but the basic parameters remain unchanged. Figure 5-6 5.2.5 Operating mode...

  • Page 29: Welding Type

    Functional characteristics MIG/MAG welding 5.2.6 Welding type Dif ferent forms of MIG/MAG processes are ref erred to as welding type. Standard (Welding with standard arc) Depending on the set combination of wire feed speed and arc voltage, the arc types short arc, transitional arc or spray arc can be used for welding.

  • Page 30: Welding Power (Operating Point)

    Functional characteristics MIG/MAG welding 5.2.7 Welding power (operating point) The welding power is adjusted according to the principle of one-knob operation. The user can set their operating point optionally as wire feed speed, welding current or material thickness. The optimum welding voltage for the operating point is calculated and set by the welding machine.

  • Page 31: Arc Length

    Functional characteristics MIG/MAG welding 5.2.7.2 Arc length When required, the arc length (welding voltage) can be adjusted for the welding task in hand by +/ – 9.9 V. Figure 5-10 5.2.7.3 Arc dynamics (choke effect) This f unction can be used to adjust the arc between a narrow, hard arc with deep penetration (positive values) and a wide and soft arc (negative values).

  • Page 32: Programs (P A 1-15)

    Functional characteristics MIG/MAG welding 5.2.8 Programs (P 1-15) Dif ferent welding jobs or positions on a workpiece require different welding programs (operating points). The f ollowing parameters are stored in each program: • Wire f eed speed and voltage correction (welding power) •...
  • Page 33 Functional characteristics MIG/MAG welding M3.7 – I/J Wire f eeder control P1-15 PC 300.NET Sof tware P1-15 MT Up/Down Welding torch P1-9 MT 2 Up/Down Welding torch P1-15 MT PC 1 Welding torch P1-15 MT PC 2 Welding torch P1-15 PM 2 Up/Down Welding torch P1-15...

  • Page 34: Program Sequence

    Functional characteristics MIG/MAG welding Example 2: Welding different positions on a workpiece (latched) Figure 5-15 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-16 Up to 16 programs (P to P ) can be defined. An operating point (wire speed, arc length correction, dynamics/choke effect) can be defined permanently in each program.

  • Page 35: Operating Modes (Functional Sequences)

    Functional characteristics MIG/MAG welding 5.2.9 Operating modes (functional sequences) 5.2.9.1 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-f lows...
  • Page 36 Functional characteristics MIG/MAG welding Non-latched mode Figure 5-18 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire f eed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 37 Functional characteristics MIG/MAG welding Special, non-latched Figure 5-19 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire f eed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P f or the time t START...
  • Page 38 Functional characteristics MIG/MAG welding Spot welding Figure 5-20 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 f eed motor runs at "creep speed" •...
  • Page 39 Functional characteristics MIG/MAG welding Latched mode Figure 5-21 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire f eed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
  • Page 40 Functional characteristics MIG/MAG welding Latched special Figure 5-22 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-flows) • Wire f eed 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 41 Functional characteristics MIG/MAG welding Special latched with changing welding method by tapping (process switching) To activate or set the function > see 5.2.10 chapter. Figure 5-23 1st cycle • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows) •...

  • Page 42: Expert Menu (Mig/Mag)

    Functional characteristics MIG/MAG welding 5.2.10 Expert menu (MIG/MAG) The Expert menu has adjustable parameters stored that don’t require regular setting. The number of pa- rameters shown may be limited, e.g. if a f unction is deactivated. Figure 5-24 Display Setting/selection Start current Setting range in percent: depending on main current Setting range, absolute: Imin to Imax.

  • Page 43: 5.2.10.1 Burn-Back

    Functional characteristics MIG/MAG welding Display Setting/selection Correction of arc length in end program P End current time (duration of end current) Burn-back time > see 5.2.10.1 chapter • ----------- Increase value > increase wire burn-back • ----------- Decrease value > decrease wire burn-back 5.2.10.1 Burn-back The wire burn-back parameter prevents the sticking of the wire electrode in the weld pool or at the contact tip at the end of the welding process.

  • Page 44: 5.2.12 Rootarc Xq / Rootarc Pulse Xq

    (molten metal) decreases and the penetration reduces. Figure 5-27 With the EWM wiredArc arc with wire control, the welding current (AMP) changes with the change of the stick-out only slightly. The compensation of the welding current takes place with an active control of wire f eed speed (DG).

  • Page 45: 5.2.14 Coldarc Xq / Coldarc Puls Xq

    Functional characteristics MIG/MAG welding 5.2.14 coldArc XQ / coldArc puls XQ Heat-reduced, low-spatter short arc for high dimensional stability welding and brazing of thin metal sheets with excellent gap-bridging. Figure 5-29 Af ter selecting the coldArc process > see 5.2.3 chapter you benefit from: •...

  • Page 46: 5.2.16.2 Switching Between Push/Pull And Intermediate Drive

    Functional characteristics TIG welding 5.2.16.2 Switching between Push/Pull and intermediate drive WARNING No improper repairs and modifications! To prevent injuries and damage to the machine, only competent personnel (authorised service personnel) are allowed to repair or modify the machine. Unauthorised manipulations will invalidate the warranty! •...

  • Page 47: Arc Ignition

    Functional characteristics TIG welding 5.3.2 Arc ignition 5.3.2.1 Liftarc Figure 5-33 The arc is ignited on contact with the workpiece: a) Caref ully place the torch gas nozzle and tungsten electrode tip onto the workpiece and press the torch trigger (liftarc current flowing, regardless of the main current set). b) Incline the torch over the torch gas nozzle to produce a gap of approx.

  • Page 48: Operating Modes (Functional Sequences)

    Functional characteristics TIG welding 5.3.3 Operating modes (functional sequences) 5.3.3.1 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-f lows Gas post-flows Non-latched Special, non-latched Latched...
  • Page 49 Functional characteristics TIG welding Non-latched mode Figure 5-34 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 50 Functional characteristics TIG welding Latched mode Figure 5-36 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 51 Functional characteristics TIG welding Latched special Figure 5-37 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 52: Mma Welding

    Functional characteristics MMA welding MMA welding 5.4.1 Welding task selection Figure 5-38 5.4.1.1 Welding current setting Figure 5-39 5.4.2 Arcforce Figure 5-40 Setting: • Negative values: rutile electrode types • Values at zero: basic electrode types • Positive values: cellulose electrode types 099-5TLPXQ-EW501 15.12.2022...

  • Page 53: Antistick

    Functional characteristics Options (additional components) 5.4.3 Antistick The Antistick feature prevents the electrode from annealing. Should the electrode stick despite the Arcforce feature, the machine au- tomatically switches to the minimum current within approx. one second. This prevents the electrode from annealing. Check the welding current setting and correct for the welding task in hand.

  • Page 54: Machine Configuration Menu

    Functional characteristics Machine configuration menu Machine configuration menu 5.8.1 Selecting, changing and saving parameters Changes to the welding parameters are only possible if the key switch is set to key position If the Xbutton function is activated, the key switch function is deactivated (see corresponding operating instructions "Control").

  • Page 55: Aligning The Cable Resistance

    Functional characteristics Machine configuration menu 5.8.1.1 Aligning the cable resistance The resistance value of cables can either be set directly or it can be aligned using the power source. The f actory setting of the power sources is 8 mΩ. This value correponds to a 5 m earth cable, a 1.5 m inter- mediate hose package and a 3 m water-cooled welding torch.

  • Page 56: Power-Saving Mode (Standby)

    Functional characteristics Special parameters (advanced settings) 1 Preparation • Switch off the welding machine. • Unscrew the gas nozzle f rom 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 57: Selecting, Changing And Saving Parameters

    Functional characteristics Special parameters (advanced settings) 5.9.1 Selecting, changing and saving parameters Figure 5-44 Display Setting/selection Wire inching / wire return ramp time 0 = -------- normal inching (10 s ramp time) 1 = -------- f ast inching (3 s ramp time) (ex works) Block program "0"...
  • Page 58 Functional characteristics Special parameters (advanced settings) Display Setting/selection Correction operation, threshold value setting 0 = -------- correction operation switched off (Ex works) 1 = -------- correction operation on "Main program (PA)" flashing Program switching with standard welding torch No program switching (factory setting) 1 = -------- Special latched 2 = -------- Special latched (n-cycle active) 3 = -------- Special latched (n-cycle sequence from any program)

  • Page 59: Reset To Factory Settings

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

  • Page 60: Display Mode For Up/Down Welding Torch With One-Digit 7-Segment Display (P3)

    Functional characteristics Special parameters (advanced settings) 5.9.3.3 Display mode for Up/Down welding torch with one-digit 7-segment display (P3) Normal display: • Program mode: Program number • Up/down operation: Welding power (0=minimum current/9=maximum current) Toggling display: • Program mode: Program number and welding procedure (P=pulse/n=not pulse) are toggled •...
  • Page 61 Functional characteristics Special parameters (advanced settings) Example for the operating point in correction operation: The wire f eed speed in a program (1 to 15) is set to 10.0 m/min. This corresponds to a welding voltage (U) of , for example, 21.9 V. When the key switch is now turned to position , welding can only be carried out with these values in this program.

  • Page 62: Switching Programs With The Standard Torch Trigger (P8)

    Functional characteristics Special parameters (advanced settings) 5.9.3.7 Switching programs with the standard torch trigger (P8) Special latched (latched absolute program sequence) • Cycle 1: absolute program 1 is run • Cycle 2: absolute program 2 is run after completion of "tstart". •...

  • Page 63: Latched/Special-Latched Tap Start (P9)

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

  • Page 64: Job List Switching (P12)

    Functional characteristics Special parameters (advanced settings) 5.9.3.11 JOB list switching (P12) Name Explanation Task-based JOB numbers are sorted by welding wires and shielding gases. When JOB list selecting, the JOB numbers may be skipped. JOB numbers correspond to the actual memory cells. Every job can Real JOB list be selected, there will be no memory cells if the selection will be skip- ped.

  • Page 65: Block Job Mode (P16)

    Functional characteristics Special parameters (advanced settings) 5.9.3.14 Block JOB mode (P16) The following accessory components support block JOB mode: • Up/Down welding torch with one-digit 7-segment display (two keys) Program 0 is always active in JOB 0 and program 1 in all other JOBs In this operating mode, up to 30 JOBs (welding tasks) divided into three blocks can be called up with ac- cessory components.

  • Page 66: Predef Ined Execution Of The Pulsed Arc Welding Process In The Pa

    Functional characteristics Special parameters (advanced settings) 5.9.3.17 Predefined execution of the pulsed arc welding process in the PA program (P20) For machine versions with pulsed arc welding procedures only. Function active (P20 = 1) • If the superPuls and welding process switching functions are available and activated, the pulse arc welding process is always executed in the main program PA (ex factory).

  • Page 67: Selection Option - Program Sequence With Welding Power Rotary Knob

    Functional characteristics Special parameters (advanced settings) 5.9.3.27 Selection option – Program sequence with welding power rotary knob (P30) Function not active • The rotary knob is locked, use the welding parameters push-button to select the welding parameters. Function active • Rotary knob can be used to select the welding parameters. 099-5TLPXQ-EW501 15.12.2022...

  • Page 68: Maintenance, Care And Disposal

    Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed.

  • Page 69: Disposing Of Equipment

    Inf ormation on returning used equipment or collections can be obtained from the respective municipal administration office. Devices can also be returned to EWM sales partners across Europe. Further inf ormation on the topic of the disposal of electrical and electronic equipment can be found on our website at: https://www.ewm-group.com/de/nachhaltigkeit.html.

  • Page 70: Rectifying Faults

    Rectifying faults Sof tware version of the machine control Rectifying faults All products are subject to rigorous production checks and final checks. If , despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dea- ler.
  • Page 71 Rectifying faults Error messages (power source) Error 6: Mains undervoltage  Mains voltage is too low. Check the mains voltages and compare them with the connection voltages of the power source.  Error 7: Low coolant level Category B  Low f low rate. Fill with coolant.
  • Page 72 Rectifying faults Error messages (power source) Error 16: Pilot arc power source - collective error Category A  The external emergency stop circuit has been interrupted. Check the emergency stop circuit and eliminate the cause of the error.   The emergency stop circuit of the power source has been activated (internally configurable). Deactivate the emergency stop circuit.
  • Page 73 Rectifying faults Error messages (power source) Error 20: Low coolant level Category B  Low f low rate. Fill with coolant.  Check coolant flow - remove kinks in the hose package.  Adjust the flow threshold  Clean the cooler. ...
  • Page 74 Rectifying faults Error messages (power source) Error 32: Error I>0  Current recording is faulty. Request service.  Error 33: Error UIST  Voltage recording is faulty. Eliminate the short circuit in the welding circuit.  Remove the external sensor voltage. ...
  • Page 75 Rectifying faults Error messages (power source) Error 48: Ignition error Category B  No ignition at process start (automated machines). Check the wire f eeding  Check the load cable connections in the welding circuit.  Clean corroded surfaces on the workpiece before welding if necessary. ...

  • Page 76: Warnings

    Rectifying faults Warnings Error 57: Slave tacho error Category B  Fault in the wire f eeder (slave drive). Check the connections (connectors, lines).   Permanent overload of the wire drive (slave drive). Do not lay the liner in tight radii. ...
  • Page 77 Rectifying faults Warnings Warning Potential cause / remedy 2 Half -wave f ailures Check process parameters. 3 Torch cooling warning Check coolant level and top up if necessary. 4 Shielding gas Check shielding gas supply. 5 Coolant flow Check min. flow rate. 6 Wire reserve Only a small amount of wire is left on the spool.

  • Page 78: Resetting Jobs (Welding Tasks) To The Factory Settings

    Rectifying faults Resetting JOBs (welding tasks) to the factory settings Warning Potential cause / remedy JOB selection was not carried out because the JOB number is 34 JOB unknown unknown. 35 Excess current on the wire feed Excess current detected on wire f eed motor slave (push/push motor slave system or intermediate drive).

  • Page 79: Resetting All Jobs

    Rectifying faults Resetting JOBs (welding tasks) to the factory settings 7.4.2 Resetting all JOBs JOBs 1–128 and 170–256 will be reset. Custom JOBs 129–169 are maintained. Figure 7-2 099-5TLPXQ-EW501 15.12.2022...

  • Page 80: Appendix

    Appendix JOB-List Appendix JOB-List Diameter JOB no. Processes Material [mm] GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 GMAW standard G3Si1 / G4Si1 100% CO2 Standard GMAW / pulse...
  • Page 81 Appendix JOB-List Diameter JOB no. Processes Material [mm] Ar-78 / He-20 / CO2-2 Standard GMAW / pulse CrNi 22 9 3 / 1.4462 (M12) coldArc / coldArc puls CrNi 19 9 / 1.4316 Ar-97.5 / CO2-2.5 (M12) coldArc / coldArc puls CrNi 19 9 / 1.4316 Ar-97.5 / CO2-2.5 (M12) coldArc / coldArc puls...
  • Page 82 Appendix JOB-List Diameter JOB no. Processes Material [mm] Standard GMAW / pulse CuSi Ar-97.5 / CO2-2.5 (M12) Standard GMAW / pulse CuSi Ar-97.5 / CO2-2.5 (M12) Standard GMAW / pulse CuAl Ar-100 (I1) Standard GMAW / pulse CuAl Ar-100 (I1) Standard GMAW / pulse CuAl Ar-100 (I1)
  • Page 83 Appendix JOB-List Diameter JOB no. Processes Material [mm] Block 2/ JOB2 Block 2/ JOB3 Block 2/ JOB4 Block 2/ JOB5 Block 2/ JOB6 Block 2/ JOB7 Block 2/ JOB8 Block 2/ JOB9 Block 2/ JOB10 Block 3/ JOB1 Block 3/ JOB2 Block 3/ JOB3 Block 3/ JOB4 Block 3/ JOB5...
  • Page 84 Appendix JOB-List Diameter JOB no. Processes Material [mm] coldArc - Mg/Mg Ar-70 / He-30 (I3) Flux cored wire rutile FCW CrNi Rutile CO2-100 (C1) Flux cored wire rutile FCW CrNi Rutile CO2-100 (C1) Standard GMAW / pulse AlMg3 Ar-100 (I1) Standard GMAW / pulse AlMg3 Ar-100 (I1)
  • Page 85 Appendix JOB-List Diameter JOB no. Processes Material [mm] Ar-78 / He-20 / CO2-2 Surf acing NiCr 6625 / 2.4831 (M12) Ar-78 / He-20 / CO2-2 Surf acing NiCr 6625 / 2.4831 (M12) Standard GMAW / pulse CrNi 25 20 / 1.4842 Ar-97.5 / CO2-2.5 (M12) Standard GMAW / pulse CrNi 25 20 / 1.4842...
  • Page 86 Appendix JOB-List Diameter JOB no. Processes Material [mm] coldArc / coldArc puls CrNi 19 12 3 / 1.4430 Ar-97.5 / CO2-2.5 (M12) CrNi 22 9 coldArc / coldArc puls Ar-97.5 / CO2-2.5 (M12) 3/1.4462/Duplex CrNi 22 9 coldArc / coldArc puls Ar-97.5 / CO2-2.5 (M12) 3/1.4462/Duplex CrNi 22 9...

  • Page 87: Parameter Overview - Setting Ranges

    Appendix Parameter overview – setting ranges Parameter overview – setting ranges 8.2.1 MIG/MAG welding Name Display Setting range Voltage correction Wire f eed speed, absolute (main program P m/min 0,00 - 20,0 Gas nominal value (option GFE) l/min 30,0 8.2.2 MMA welding Name Display...

  • Page 88: Searching For A Dealer

    Appendix Searching for a dealer Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-5TLPXQ-EW501 15.12.2022...

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