EWM LP-S Operating Instructions Manual
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EWM LP-S Operating Instructions Manual

EWM LP-S Operating Instructions Manual

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Operating instructions
Control
LP-S (M3.7X-U)
EN
099-0M37XU-EW501
Observe additional system documents!
27.05.2024

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Summary of Contents for EWM LP-S

  • Page 1 Operating instructions Control LP-S (M3.7X-U) 099-0M37XU-EW501 Observe additional system documents! 27.05.2024...
  • 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......................5 Notes on using these operating instructions ............... 5 Explanation of icons ....................6 Saf ety instructions ....................7 Transport and installation ..................10 3 Intended use ........................12 Use and operation solely with the following machines ..........12 Software version ....................12 Documents which also apply ...................12...
  • Page 4 Contents Notes on using these operating instructions 5.3.2 Welding current setting ................41 5.3.3 Arc ignition .....................42 5.3.3.1 Lif tarc ..................42 5.3.4 Expert menu (TIG) ...................43 5.3.5 Operating modes (f unctional sequences).............45 5.3.5.1 Explanation of signs and functions ..........45 5.3.5.2 Automatic cut-out ...............49 MMA welding......................50 5.4.1 Welding task selection ................50...

  • Page 5: For Your Safety

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

  • Page 6: Explanation Of Icons

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

  • Page 7: 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 saf ety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •...
  • Page 8 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 9 For your safety Saf ety instructions CAUTION Smoke and gases! Smoke and gases may lead to shortness of breath and poisoning! The ultraviolet radia- tion of the arc may also convert solvent vapours (chlorinated hydrocarbon) into poiso- nous phosgene. • Ensure suf f icient f resh air! •...

  • Page 10: Transport And Installation

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

  • Page 12: Intended Use

    • Do not improperly modif y or convert the equipment! Use and operation solely with the following machines This description may be applied only to machines with the M3.7X-U (LP-S) machine control. Software version The software version of the machine control can be displayed in the machine configuration menu (menu Srv) >...

  • Page 13: Part Of The Complete Documentation

    Intended use Documents which also apply 3.3.1 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 14: 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 15: Control Section A

    Machine control – Operating elements Overview of control sections 4.1.1 Control section A Figure 4-2 Item Symbol Description Welding task push-button (JOB) • ----------- Short press of a button: Fast switching of the available welding procedures in the selected basic parameters (material/wire/gas). •...

  • Page 16: Control Section B

    Machine control – Operating elements Overview of control sections Item Symbol Description push-button JOB Favourites > see 4.3.5 chapter •-----------Pressing the push-button brief ly: Loading Favourites •-----------Press and hold the push-button (>2 s): Saving as a Favourite •-----------Press and hold the push-button (>12 s): Deleting a Favourite Push-button gas test / rinse hose package >...
  • Page 17 Machine control – Operating elements Overview of control sections Item Symbol Description Signal light for the welding program > see 5.2.5 chapter Display of the current program number in the welding data display. Correction voltage arc length signal light Display of correction voltage arc length in volts. Welding power signal light Display of welding power in kilowatts.

  • Page 18: 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 f or 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 19: Welding Power Setting

    Machine control – Operating elements Operating the machine control 4.3.2 Welding power setting The welding power is adjusted with the rotary knob (click wheel) for welding power. You can also adjust the parameters in the operation sequence or settings in the various machine menus. MIG/MAG settings The welding power (heat input into the material) can be changed by setting the f ollowing three parame- ters:...

  • Page 20: 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 21: 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 f avourite memory push-button. Af ter 2 seconds, the signal light of the f avourite status turns green af ter another 5 s, the signal light starts f lashing red af ter another 5 s the signal light goes out •...

  • Page 22: Functional Characteristics

    Functional characteristics Shielding gas supply (shielding gas cylinder f or 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 f orm.

  • Page 23: 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-f ree inching of the wire electrode af ter 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 24: 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 25: Welding Task Selection

    Functional characteristics MIG/MAG welding 5.2.3 Welding task selection This machine series of f ers simple operation and a wide rang e of f unctions. • JOBs (welding tasks consisting of welding procedure, type of material, wire diameter and type of shiel- ding gas) pre-def ined f or all standard welding tasks.

  • Page 26: Welding Procedure

    Functional characteristics MIG/MAG welding 5.2.3.2 Welding procedure Af ter setting the basic parameters, switching between the MIG/MAG welding procedures f orceArc and rootArc is possible (provided there is a corresponding combination of basic parameters). The process change will also change the JOB number, but the basic parameters remain unchanged. Figure 5-6 5.2.3.3 Operating mode...

  • Page 27: Welding Power (Operating Point)

    Functional characteristics MIG/MAG welding 5.2.3.5 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 28: Arc Dynamics (Choke Effect)

    Functional characteristics MIG/MAG welding 5.2.3.7 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). In addition, the selected settings are displayed with signal lights below the rotary knobs.
  • Page 29 Functional characteristics MIG/MAG welding Example 1: Welding workpieces with different sheet metal thicknesses (non-latched) Figure 5-13 Example 2: Welding different positions on a workpiece (latched) Figure 5-14 Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special) Figure 5-15 Up to 15 programs (P to P...

  • Page 30: Program Sequence

    Functional characteristics MIG/MAG welding 5.2.6 Program sequence Certain materials, aluminium for example, require special functions for reliable and high-quality welding. In this case, the special latched mode is used with the f ollowing programs: • Start program P (avoidance of cold welds at start of seam) START •...

  • Page 31: Expert Menu (Mig/Mag)

    Functional characteristics MIG/MAG welding 5.2.7 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 5-17 Display Setting/selection Start current (as percentage, dependent on main current) Correction of arc length in start program P START...

  • Page 32: Burn-Back

    Functional characteristics MIG/MAG welding Display Setting/selection End-crater current Setting range in percent: depending on main current Setting range, absolute: Imin to Imax. Correction of arc length in end program P End current time (duration of end current) Burn-back time > see 5.2.7.1 chapter •...
  • Page 33 Functional characteristics MIG/MAG welding Non-latched mode Figure 5-18 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-f lows). • Wire f eed motor runs at “creep speed”. • Arc ignites af ter the wire electrode makes contact with the workpiece; welding current f lows. •...
  • Page 34 Functional characteristics MIG/MAG welding Special, non-latched Figure 5-19 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-f lows) • Wire f eed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is f lowing (start program P f or the time t START...
  • Page 35 Functional characteristics MIG/MAG welding Spot welding Figure 5-20 Start and slope times from the start program must be added to the spot time. 1st cycle • Press and hold torch trigger • Shielding gas is expelled (gas pre-f lows) • Wire f eed motor runs at "creep speed" •...
  • Page 36 Functional characteristics MIG/MAG welding Latched mode Figure 5-21 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-f lows) • Wire f eed motor runs at “creep speed”. • Arc ignites af ter the wire electrode makes contact with the workpiece; welding current f lows. •...

  • Page 37: Automatic Cut-Out

    Functional characteristics MIG/MAG welding Latched special Figure 5-22 Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-f lows) • Wire f eed motor runs at “creep speed”. • Arc ignites after the wire electrode makes contact with the workpiece, welding current is f lowing (start program P START The slope on main program P...

  • Page 38: Forcearc / Forcearc Puls

    Functional characteristics MIG/MAG welding 5.2.9 forceArc / forceArc puls Heat-reduced, directionally-stable and powerf ul arc with deep f usion penetration f or the upper power range. Figure 5-23 • Smaller included angle due to deep penetration and directionally stable arc •...

  • Page 39: Conventional Mig/Mag Welding (Gmaw Non Synergic)

    Functional characteristics MIG/MAG welding 5.2.11 Conventional MIG/MAG Welding (GMAW non synergic) Applications, for example for exotic welding wires, may require special settings of the welding parame- ters. In this operating method, wire f eed speed and welding voltage can be determined independently of each other over the entire setting range.

  • Page 40: Arc Dynamics (Choke Effect)

    Functional characteristics MIG/MAG welding 5.2.11.2 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). In addition, the selected settings are displayed with signal lights below the rotary knobs.

  • Page 41: Tig Welding

    Functional characteristics TIG welding Display Setting/selection Wire creep • ----------- Increase the value > higher wire creep speed • ----------- Decrease the value > lower wire creep speed TIG welding 5.3.1 Welding task selection Figure 5-29 5.3.2 Welding current setting Figure 5-30 099-0M37XU-EW501 27.05.2024...

  • Page 42: Arc Ignition

    Functional characteristics TIG welding 5.3.3 Arc ignition 5.3.3.1 Liftarc Figure 5-31 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 (lif tarc current f lowing, regardless of the main current set). b) Incline the torch over the torch gas nozzle to produce a gap of approx.

  • Page 43: Expert Menu (Tig)

    Functional characteristics TIG welding 5.3.4 Expert menu (TIG) 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 5-32 Display Setting/selection Gas pre-flow time Start current (as percentage, dependent on main current) Start time (duration of start current)
  • Page 44 Functional characteristics TIG welding Display Setting/selection Gas post-flow time 099-0M37XU-EW501 27.05.2024...

  • Page 45: Operating Modes (Functional Sequences)

    Functional characteristics TIG welding 5.3.5 Operating modes (functional sequences) 5.3.5.1 Explanation of signs and functions Symbol Meaning Pressing the torch trigger Releasing the torch trigger Tap the torch trigger (brief ly press and release) Shielding gas is f lowing Welding power Gas pre-f low Gas post-f low Non-latched...
  • Page 46 Functional characteristics TIG welding Latched mode Figure 5-34 Selection • Select latched operating mode Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-f lows) The arc is ignited using liftarc. • Welding current f lows with pre-selected setting. Step 2 •...
  • Page 47 Functional characteristics TIG welding Special, non-latched Figure 5-35 Selection • Select non-latched special mode Step 1 • Press and hold torch trigger • Shielding gas is expelled (gas pre-f lows) The arc is ignited using liftarc. • Welding gas f lows with pre-selected setting in start program “P ”.
  • Page 48 Functional characteristics TIG welding Spot welding Figure 5-36 Start and slope times from the start program must be added to the spot time. 1st cycle • Press and hold the torch trigger. • Shielding gas is f lowing (gas pre-f low). The arc striking takes place with Liftarc.

  • Page 49: Automatic Cut-Out

    Functional characteristics TIG welding Latched special Figure 5-37 Selection • Select special latched operating mode 1st cycle • Press and hold the torch trigger. • Shielding gas is f lowing (gas pre-f low). The arc striking takes place with Liftarc. •...

  • Page 50: Mma Welding

    Functional characteristics MMA welding MMA welding 5.4.1 Welding task selection Figure 5-38 5.4.2 Welding current setting Figure 5-39 5.4.3 Arcforce Figure 5-40 Setting: • Negative values: rutile electrode types • Values at zero: basic electrode types • Positive values: cellulose electrode types 099-0M37XU-EW501 27.05.2024...

  • Page 51: Hotstart

    Functional characteristics MMA welding 5.4.4 Hotstart The f unction hot start ensures a secure igniting of the arc and a sufficient heating to the still cold parent metal at the beginning of the welding process. The ignition takes place here with increased current (hot start current) over a certain time (hot start time).

  • Page 52: Machine Configuration Menu

    Functional characteristics Machine conf iguration menu Machine configuration menu 5.5.1 Selecting, changing and saving parameters Figure 5-44 Display Setting/selection Lead resistance 1 Lead resistance f or the f irst welding circuit 0 mΩ–60 mΩ (8 mΩ ex works). Only qualified service personnel may change the parameters! Only qualified service personnel may change the parameters! Time-based power-saving mode >...

  • Page 53: Aligning The Cable Resistance

    Functional characteristics Machine conf iguration menu 5.5.2 Aligning the cable resistance The resistance value of the cables can be set directly or adjusted by the power source. The power source cable resistance value is set to 8 mΩ when delivered. This value corresponds to an earth cable length of 5 m, an intermediate hose package length of 1.5 m and a water-cooled welding torch length of 3 m.

  • Page 54: Power-Saving Mode (Standby)

    Functional characteristics Power-saving mode (Standby) 1 Preparation • Switch of f the welding machine. • Unscrew the gas nozzle f rom the welding to rch. • Trim the welding wire so that it is f lush with the contact tip. •...

  • Page 55: Special Parameters (Advanced Settings)

    Functional characteristics Special parameters (advanced settings) Special parameters (advanced settings) Special parameters (P1 to Pn) are applied for customer-specific configuration of machine f unctions. This allows the user maximum f lexibility in optimising their requirements. These settings are not configured directly on the machine control since a regular setting of the parame- ters is generally not required.

  • Page 56: Special Parameters In Detail

    Functional characteristics Special parameters (advanced settings) Display Setting/selection Tapping time 0 = -------- The tapping f unction is switched of f 1 = -------- 320 ms (f actory setting) 2 = -------- 640 ms HOLD function 0 = -------- HOLD values are not displayed 1 = -------- HOLD values are displayed (Ex works) Program selection with standard torch trigger 0 = -------- no program selection (Ex works)

  • Page 57: Units System (P29)

    Functional characteristics Special parameters (advanced settings) 5.7.2.8 Units system (P29) Function not active • Metric metric units are displayed. Function active • Imperial units are displayed. 5.7.3 Reset to factory settings All special parameters saved by the user will be overwritten by the factory settings! Figure 5-47 099-0M37XU-EW501 27.05.2024...

  • Page 58: 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 59: Disposing Of Equipment

    Inf ormation on returning used equipment or collections can be obtained f rom the respective municipal administration of f ice. 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 60: 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 f ails to work at any time, please check the product using the following flowchart. If none of the f ault rectif ication procedures described leads to the correct functioning of the product, please inform your authorised dea- ler.
  • Page 61 Rectifying faults Error messages (power source) Error 6: Mains undervoltage Category A  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 ...
  • Page 62 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 conf igurable). Deactivate the emergency stop circuit.
  • Page 63 Rectifying faults Error messages (power source) Error 20: Low coolant level Category B  Low f low rate. Fill with coolant.  Check coolant f low - remove kinks in the hose package.  Adjust the f low threshold  Clean the cooler.
  • Page 64 Rectifying faults Error messages (power source) Error 26: Excess pilot arc module temperature Category A  The power source is overheating. Allow the switched-on machine to cool.   Fan is blocked, dirty or f aulty. Check the f an and clean or replace it. ...
  • Page 65 Rectifying faults Error messages (power source) Error 40: Electronics error  Error I>0 Request service.  Error 47: Radio link (BT) Category B  Connection error between the welding machine and peripheral unit. Note the documentation f or the data interf ace with radio transmission. ...
  • Page 66 Rectifying faults Error messages (power source) Error 56: Mains phase failure  One phase of the mains voltage has f ailed. Check the mains connection, mains plug and mains f uses.  Error 57: Slave tacho error Category B  Fault in the wire f eeder (slave drive). Check the connections (connectors, lines).

  • Page 67: Warnings

    Rectifying faults Warnings Warnings Depending on the display options of the machine display, a warning message is displayed as f ollows: Display type - machine control Display Graphic display two 7-segment displays one 7-segment display The cause of the warning is indicated by a corresponding warning number (see table). •...
  • Page 68 Rectifying faults Warnings Warning Potential cause / remedy 24 Coolant f low warning Check the coolant supply. Check the coolant level and top up if necessary. Check f low and switching thresholds. 25 Flow 2 reserved 26 Flow 3 reserved 27 Flow 4 reserved 28 Wire stock warning...

  • Page 69: Resetting Jobs (Welding Tasks) To The Factory Settings

    Rectifying faults Resetting JOBs (welding tasks) to the f actory settings Resetting JOBs (welding tasks) to the factory settings All customised welding parameters that are stored will be replaced by the factory settings. 7.4.1 Resetting a single JOB Figure 7-1 7.4.2 Resetting all JOBs Figure 7-2...

  • Page 70: Appendix

    Appendix JOB-List Appendix JOB-List Diameter JOB no. Procedure 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 Standard GMAW / pulse G3Si1 / G4Si1 Ar-82 / CO2-18 (M21) Standard GMAW / pulse G3Si1 / G4Si1 Ar-82 / CO2-18 (M21)
  • Page 71 Appendix JOB-List Diameter JOB no. Procedure Material [mm] Flux-cored wire rutile FCW CrNi Rutile CO2-100 (C1) Flux-cored wire metal FCW CrNi Metal Ar-97,5 / CO2-2,5 (M12) Flux-cored wire metal FCW CrNi Metal Ar-97,5 / CO2-2,5 (M12) Flux-cored wire rutile FCW CrNi Rutile Ar-82 / CO2-18 (M21) Flux-cored wire rutile FCW CrNi Rutile...

  • Page 72: Parameter Overview - Setting Ranges

    Appendix Parameter overview – setting ranges Parameter overview – setting ranges 8.2.1 MIG/MAG welding Name Display Setting range Gas pre-f low time in JOB 188 Wire creep in JOB 188 (depending on the main program P Wire f eed speed in the start program P (depending on START the main program P...

  • Page 73: Mma Welding

    Appendix Parameter overview – setting ranges 8.2.3 MMA welding Name Display Setting range Hot start current, percentage of the main current Hot start time 20,0 Arcf orce 099-0M37XU-EW501 27.05.2024...

  • Page 74: Searching For A Dealer

    Appendix Searching f or a dealer Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-0M37XU-EW501 27.05.2024...

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