EWM Expert 3.0 MIG/MAG Operating Instructions Manual
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EWM Expert 3.0 MIG/MAG Operating Instructions Manual

EWM Expert 3.0 MIG/MAG Operating Instructions Manual

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Operating instructions
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Expert 3.0 MIG/MAG
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099-00L20M-EW501
Observe additional system documents!
28.01.2025

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Summary of Contents for EWM Expert 3.0 MIG/MAG

  • Page 1 Operating instructions Control Expert 3.0 MIG/MAG 099-00L20M-EW501 Observe additional system documents! 28.01.2025...

  • Page 2: General Instructions

    +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 form 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 Safety instructions ........................8 Transport and installation ....................11 3 Intended use ..........................
  • Page 4 Contents Notes on using these operating instructions 5.4.7.1 Explanation of signs and functions ............35 5.4.7.2 Automatic cut-out .................. 47 5.4.8 coldArc XQ / coldArc puls XQ ................48 5.4.9 forceArc XQ / forceArc puls XQ ................48 5.4.10 rootArc XQ / rootArc pulse XQ................49 5.4.11 acArc puls XQ .......................
  • Page 5 Contents Notes on using these operating instructions 8.4.1.24 Mode switching at welding start (P27) ..........69 8.4.1.25 Error threshold electronic gas flow control (P28) ........69 8.4.1.26 Units system (P29) ................69 8.4.1.27 Selection option – Program sequence with welding power rotary knob (P30) .....................

  • 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. • Safety 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 Safety instructions Safety instructions WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! •...
  • Page 9 For your safety Safety 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 Safety 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 poison- ous phosgene. • Ensure sufficient fresh air! •...

  • 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 in- troduction 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

    Intended use Applications Intended use WARNING Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and stand- ards applicable for use in industry and trade. It may only be used for the welding proce- dures indicated at the rating plate.

  • Page 14: Documents Which Also Apply

    Intended use Documents which also apply Documents which also apply • Operating instructions for the connected welding machines • Documents of the optional expansions 3.4.1 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 compo- nents, especially the safety instructions! The illustration shows a general example of a welding system.

  • Page 15: Product Description - Quick Reference

    Product description – quick reference Operating elements Product description – quick reference Operating elements Figure 4-1 Item Symbol Description System push-button (main menu) • ----------- Display and configuration of system settings > see 5.2 chapter. • ----------- Protection against accidental adjustment (lock function) > see 5.3 chapter. Push-buttons for JOB-favourites >...
  • Page 16 Product description – quick reference Operating elements Item Symbol Description Push-button UL (bottom left) with multiple functions • ---------- Setting the operating mode in the main menu > see 5.4.7 chapter • ---------- Double allocation Hotkey > see 5.1.4 chapter (long button press). Push-button UR (bottom right) with multiple functions •...

  • Page 17: Machine Display

    Product description – quick reference Machine display Machine display The machine display shows all the information relevant to the user as text and/or graphics. 4.2.1 Loading screen The loading bar on the loading screen shows the progress of the loading process. Basic information such as the set system language >...

  • Page 18: Status Bar

    Product description – quick reference Machine display 4.2.1.2 Status bar The status bar displays system and process states. Symbols with a green background in the status dis- play indicate an active parameter. The overview of status and screen symbols is summarised in the table screen symbols >...

  • Page 19: Main Screen (Homescreen)

    Product description – quick reference Machine display Symbol Description Locked; selected function is not available with the current access rights or procedure combination - check access rights (Xbutton). Local network (LAN) Pulse settings Program (P0-P15) > see 4.2.5 chapter Prog After welding, the last welded values (hold values) are displayed.
  • Page 20 Product description – quick reference Machine display Example: TIG welding Figure 4-5 Example: MMA welding Figure 4-6 099-00L20M-EW501 28.01.2025...

  • Page 21: Quick Menu

    Product description – quick reference Machine display 4.2.3.1 Quick menu Use the quick menu to define the display of process parameters. The display of the parameters (except for wire feed speed or main current) can be shown or hidden. • Press the push-button Home Figure 4-7 4.2.4...

  • Page 22: Welding Phases

    Product description – quick reference Machine display 4.2.4.1 Welding phases Figure 4-9 Item Description Start phase P START The start phase in the welding process ensures correct burning and melting of the materials at the start of seam to ensure a stable connection between the workpieces. A clean ignition and correct heat supply are crucial for a consistent weld.

  • Page 23: Operating The Machine Control

    Operating the machine control Machine display Operating the machine control After switching on the device, the start-up process of the machine control begins (switching on until ready to weld) and the loading screen with the loading bar > see 4.2.1 chapter is shown in the machine display. After the start process, the machine display will split into the main screen >...

  • Page 24: Advanced Settings

    Operating the machine control Advanced settings Advanced settings Advanced settings in the menu are additional parameters, settings or organisational program items. 5.1.1 JOB finder The JOB finder is an auxiliary function for finding the required welding task (JOB). Figure 5-2 5.1.2 JOB Manager (organising welding tasks) Figure 5-3...

  • Page 25: Hotkey Double Allocation

    Operating the machine control Advanced settings 5.1.4 Hotkey double allocation Hotkeys are shortcut keys for quick access to freely selectable machine functions. These machine func- tions can be set as a dual function on the push-buttons OL, UL, UR and OR. The push-buttons can be assigned in the Hotkeys menu.

  • Page 26: System (Main Menu)

    Operating the machine control System (main menu) System (main menu) 5.2.1 System settings System settings Language  Operating panel   System settings  Brightness Units  Program 0 (P0) can be adjusted from the power source  Status bar ...

  • Page 27: Adjustment

    Operating the machine control System (main menu) Power source   Energy saving function  Standby time  Log off user in standby mode Control  Operation without WF   Lock program 0 > see 8.4.1.2 chapter  Correction operation > see 8.4.1.6 chapter JOB list switching >...

  • Page 28: Job Manager (Organising Welding Tasks)

    Operating the machine control System (main menu) 5.2.3 JOB Manager (organising welding tasks) JOB manager  JOB selection  Favourites Delete favourites  Load favourites  Save favourites to USB flash drive  Copy   Target JOB   Start Reset ...

  • Page 29: Service

    Operating the machine control System (main menu) 5.2.5 Service Service  Contacting  EWM GmbH  Ihr Händler  Visitenkarte laden (USB) Visitenkarte löschen  Vorlage speichern (USB)  Safely remove the USB flash drive  Searching for a dealer ...

  • Page 30: Lock Function

    Operating the machine control Lock function Temperatures   Housing inside  Secondary transformer  Primary heatsink  Sensors  Coolant flow Lock function The lock function protects against accidental changes to the machine settings. All operating elements are deactivated when the function is activated and signalled by the display . Press and hold (> 3 s) the push-button to enable or disable the function.

  • Page 31: Job Finder

    Operating the machine control MIG/MAG welding 5.4.2 JOB finder The JOB finder is an auxiliary function for finding the required welding task (JOB). Figure 5-7 5.4.2.1 Welding procedure After 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).

  • Page 32: Welding Type

    Operating the machine control MIG/MAG welding 5.4.3 Welding type Different forms of MIG/MAG processes are referred 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 33: Arc Length

    This function is e.g. used for thin sheet welding to reduce the heat input in a controlled manner or for po- sitional welding without the need for weaving. superPuls in combination with EWM welding processes offers a variety of options. For example, to weld vertical-up welds without using the so-called Christmas tree technique, the corresponding superpuls vari- ant (depending on the material) is activated when program 1 >...

  • Page 34: Gas Test

    Operating the machine control MIG/MAG welding 5.4.5.1 Gas test Figure 5-11 5.4.5.2 Purge hose package 300s Figure 5-12 5.4.5.3 Wire inching The wire inching function is used for potential- and gas-free inching of the wire electrode after the wire spool change. By pressing and holding the wire inching push-button, the wire inching speed increases in a ramp function of 1 m/min up to the set maximum value (special parameter P1 >...

  • Page 35: Operating Modes

    Operating the machine control MIG/MAG welding 5.4.7 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). 5.4.7.1 Explanation of signs and functions Symbol Meaning Pressing the torch trigger...
  • Page 36 Operating the machine control MIG/MAG welding Non-latched mode Figure 5-13 1st cycle • Press and hold the torch trigger. • Shielding gas is flowing (gas pre-flow). • Wire feed motor runs at wire creep speed. • Arc ignites after the wire electrode hits the workpiece, welding current flows.
  • Page 37 Operating the machine control MIG/MAG welding Non-latched operation with superPuls Figure 5-14 1st cycle • Press and hold the torch trigger. • Shielding gas is flowing (gas pre-flow). • Wire feed motor runs at wire creep speed. • Arc ignites after the wire electrode hits the workpiece, welding current flows.
  • Page 38 Operating the machine control MIG/MAG welding Special, non-latched Figure 5-15 1st cycle • Press and hold the torch trigger. • Shielding gas is flowing (gas pre-flow). • Wire feed motor runs at wire creep speed. • Arc ignites after the wire electrode hits the workpiece, welding current flows (start phase P for the duration of start).
  • Page 39 Operating the machine control MIG/MAG welding Spot welding Figure 5-16 Start duration and slope time start from the start phase must be added to the spot time. 1st cycle • Press and hold the torch trigger. • Shielding gas is flowing (gas pre-flow). •...
  • Page 40 Operating the machine control MIG/MAG welding Special, non-latched with superPuls Figure 5-17 1st cycle • Press and hold the torch trigger. • Shielding gas is flowing (gas pre-flow). • Wire feed motor runs at wire creep speed. • Arc ignites after the wire electrode hits the workpiece. Welding current flows (start phase P ) for the duration of start.
  • Page 41 Operating the machine control MIG/MAG welding Latched mode Figure 5-18 1st cycle • Press and hold the torch trigger. • Shielding gas is flowing (gas pre-flow). • Wire feed motor runs at wire creep speed. • Arc ignites after the wire electrode hits the workpiece. Welding current flows. •...
  • Page 42 Operating the machine control MIG/MAG welding Latched mode with superPuls Figure 5-19 1st cycle: • Press and hold the torch trigger. • Shielding gas is flowing (gas pre-flow). • Wire feed motor runs at wire creep speed. • Arc ignites after the wire electrode hits the workpiece. Welding current flows.
  • Page 43 Operating the machine control MIG/MAG welding Latched with changing welding method (process switching) Exclusively for devices with pulsed arc welding type > see 3.1 chapter. Figure 5-20 1st cycle: • Press and hold the torch trigger. • Shielding gas is flowing (gas pre-flow). •...
  • Page 44 Operating the machine control MIG/MAG welding Latched special Figure 5-21 1st cycle • Press and hold the torch trigger. • Shielding gas is flowing (gas pre-flow). • Wire feed motor runs at wire creep speed. • Arc ignites after the wire electrode hits the workpiece, welding current flows (start phase P START The slope time to the main phase P...
  • Page 45 Operating the machine control MIG/MAG welding Special latched with changing welding method by tapping (process switching) Exclusively for devices with pulsed arc welding type > see 3.1 chapter. Figure 5-22 1st cycle • Press and hold the torch trigger. • Shielding gas is flowing (gas pre-flow).
  • Page 46 Operating the machine control MIG/MAG welding Special latched with changing welding method (process switching) Exclusively for devices with pulsed arc welding type > see 3.1 chapter. Figure 5-23 1st cycle • Press and hold the torch trigger. • Shielding gas is flowing (gas pre-flow). •...

  • Page 47: Automatic Cut-Out

    Operating the machine control MIG/MAG welding Special, latched with superpulse Figure 5-24 1st cycle • Press and hold the torch trigger. • Shielding gas is flowing (gas pre-flow). • Wire feed motor runs at “wire creep speed”. • Arc ignites after the wire electrode hits the workpiece. Welding current flows (start phase P for the duration of start).

  • Page 48: Coldarc Xq / Coldarc Puls Xq

    Operating the machine control MIG/MAG welding 5.4.8 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 5-25 After selecting the coldArc process > see 5.4.1 chapter you benefit from: •...

  • Page 49: 5.4.10 Rootarc Xq / Rootarc Pulse Xq

    Operating the machine control MIG/MAG welding 5.4.10 rootArc XQ / rootArc pulse XQ Short arc with perfect weld modelling capabilities for effortless gap bridging, especially for root welding Figure 5-27 • Reduced spatter compared to standard short arc • Good root formation and secure sidewall fusion •...

  • Page 50: 5.4.12 Wiredarc

    Operating the machine control MIG/MAG welding Item Symbol Description Cleaning and preheating the wire in the negative phase The arc dynamics can be used to influence the negative phase in the welding process: Dynamics setting (operating element) Welding properties Left turn (more minus), •...

  • Page 51: 5.4.13 Standard Mig/Mag Torch

    Operating the machine control MIG/MAG welding 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 feed speed (DG).

  • Page 52: 5.4.15 Aligning The Cable Resistance

    Operating the machine control MIG/MAG welding 5.4.15 Aligning the cable resistance To ensure optimum welding properties, the electric cable resistance should be aligned again whenever an accessory component such as the welding torch or the intermediate hose package (AW) has been changed.

  • Page 53: Tig Welding

    TIG welding Welding task selection TIG welding Welding task selection Setting the welding task JOB 127 in JOB manager > see 5.2.3 chapter. 6.1.1 Arc ignition 6.1.1.1 Liftarc Figure 6-1 The arc is ignited on contact with the workpiece: a) Carefully 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).

  • Page 54: Setting The Shielding Gas Volume (Gas Test)/Rinse Hose Package

    TIG welding Setting the shielding gas volume (gas test)/rinse hose package Setting the shielding gas volume (gas test)/rinse hose package • Slowly open the gas cylinder valve. • Open the pressure regulator. • Switch on the power source at the main switch. •...

  • Page 55: Pulse Welding

    TIG welding Pulse welding Pulse welding The functional processes behave the same as with standard welding. However, there is also switching back and forth between main phase A (pulse current) and main phase B (pulse-pause current) with the set times of duration A and duration B. Figure 6-2 099-00L20M-EW501 28.01.2025...

  • Page 56: Mma Welding

    MMA welding Hotstart MMA welding Setting the welding task JOB 128 in JOB manager > see 5.2.3 chapter. Hotstart The function 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 57: Functional Characteristics

    Functional characteristics JOB Manager (organising welding tasks) Functional characteristics JOB Manager (organising welding tasks) Use the JOB Manager to organise the welding tasks in the welding system. The following operations can be carried out in the JOB Manager: • JOB loading for active use (alternatively, use the JOB finder function). •...

  • Page 58: Job Favourites

    Functional characteristics JOB favourites JOB favourites JOB- favourites are additional memory locations for saving frequently used welding tasks, programs and their settings and loading them when required. The status of the Favourites (loaded, changed, not loaded) is indicated by signal lights. •...

  • Page 59: Deleting Saved Favourites

    Functional characteristics JOB favourites 8.2.3 Deleting saved Favourites Figure 8-5 • Press and hold the favourite memory push-button. After 2 seconds, the status display for Favourites turns green after another 5 s, the signal light starts flashing red after another 5 s the signal light goes out •...

  • Page 60: Access Permission (Xbutton)

    Access permission (Xbutton) Access permission (Xbutton) Xbutton is a system for the intelligent control of access rights in EWM welding machines and components that are equipped with Expert control. Using convenient, programmable recognition memories (Xbutton), varying usage rights can be granted to users.
  • Page 61 Functional characteristics Special parameters (advanced settings) Display Setting/selection Wire inching / wire return ramp time 0 = -------- normal inching (10 s ramp time) 1 = -------- fast inching (3 s ramp time) (ex works) Block program "0" 0 = --------P0 enabled 1 = --------P0 blocked (Ex works) Display mode for Up/Down welding torch with one-digit 7-segment display (two keys)

  • Page 62: Special Parameters In Detail

    Functional characteristics Special parameters (advanced settings) Display Setting/selection Program selection with standard torch trigger 0 = ------- no program selection (Ex works) 1 = ------- program selection possible Average value display for superPuls 0 = ------- Function switched off. 1 = ------- Function switched on (ex factory). Specification of pulse arc welding in main phase A 0 = ------- The pulse arc welding specification in main phase A is switched off.

  • Page 63: Display Mode For Up/Down Welding Torch With One-Digit 7-Segment Display (P3)

    Functional characteristics Special parameters (advanced settings) 8.4.1.3 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 64 Functional characteristics Special parameters (advanced settings) Example for the operating point in correction operation: The wire feed 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 65: Switching Programs With The Standard Torch Trigger (P8)

    Functional characteristics Special parameters (advanced settings) 8.4.1.7 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 66: 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 the torch trigger. • Shielding gas is flowing (gas pre-flow). • Wire feed motor runs at wire creep speed. •...

  • Page 67: Job List Switching (P12)

    Functional characteristics Special parameters (advanced settings) 8.4.1.11 JOB list switching (P12) Value Name Explanation Task-based JOB numbers are sorted by welding wires and shielding gases. JOB list When selecting, the JOB numbers may be skipped. Real JOB list JOB numbers correspond to the actual memory cells. Every job can be selected, there will be no memory cells if the selection will be skipped.

  • Page 68: Block Job Mode (P16)

    Functional characteristics Special parameters (advanced settings) 8.4.1.14 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 69: Predefined Execution Of The Pulsed Arc Welding Process In The Pa Program (P20)

    Functional characteristics Special parameters (advanced settings) 8.4.1.17 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) • When the superPuls and welding procedure switching functions are available and switched on, the pulse arc welding procedure is always carried out in main phase P (factory set).

  • Page 70: Selection Option - Program Sequence With Welding Power Rotary Knob (P30)

    Functional characteristics Energy saving function (Standby) 8.4.1.27 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.

  • Page 71: 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 72: Disposing Of Equipment

    Information 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 information 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 73: Rectifying Faults

    Rectifying faults Warnings 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 74 Rectifying faults Warnings Warning Potential cause / remedy 20 Coolant temperature warning Check the coolant level and top up if necessary. 21 Excess temperature 2 reserved 22 Excess temperature 3 reserved 23 Excess temperature 4 reserved 24 Coolant flow warning Check the coolant supply.

  • Page 75: Error Messages (Power Source)

    Rectifying faults Error messages (power source) 10.2 Error messages (power source) The possible error numbers displayed depend on the machine series and version! Depending on the options of the machine display, a fault is shown as follows: Display type - machine control Display Graphic display two 7-segment displays...
  • Page 76 Rectifying faults Error messages (power source) Error 7: Low coolant level Category B  Low flow rate. Fill with coolant.  Check coolant flow - remove kinks in the hose package.  Adjust the flow threshold  Clean the cooler. ...
  • Page 77 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 78 Rectifying faults Error messages (power source) Error 20: Low coolant level Category B  Low flow rate. Fill with coolant.  Check coolant flow - remove kinks in the hose package.  Adjust the flow threshold  Clean the cooler. ...
  • Page 79 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 faulty. Check the fan and clean or replace it. ...
  • Page 80 Rectifying faults Error messages (power source) Error 40: Electronics error  Error in the power supply of the electronics Request service.  Error 47: Radio link (BT) Category B  Connection error between the welding machine and peripheral unit. Note the documentation for the data interface with radio transmission. ...
  • Page 81 Rectifying faults Error messages (power source) Error 55: Excess wire feeder current Category B  Excess current detected in the wire feed mechanism. Do not lay the liner in tight radii.  Check the liner for ease of movement.  Error 56: Mains phase failure ...

  • Page 82: Resetting Welding Parameters To The Factory Settings

    Rectifying faults Resetting welding parameters to the factory settings 10.3 Resetting welding parameters to the factory settings All customised welding parameters that are stored will be replaced by the factory settings. Selection Service  Reset  Factory settings  Advanced (service area) 10.4 The software versions of the system components Identifying the machine software is the basis for quick troubleshooting by authorised service personnel.

  • Page 83: Appendix

    Appendix JOB list Appendix 11.1 JOB list JOB no. Procedure Material Diameter [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...
  • Page 84 Appendix JOB list JOB no. Procedure Material Diameter [mm] Standard GMAW / pulse CrNi 22 9 3 / 1.4462 Ar-78 / He-20 / CO2-2 (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 85 Appendix JOB list JOB no. Procedure Material Diameter [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 86 Appendix JOB list JOB no. Procedure Material Diameter [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 87 Appendix JOB list JOB no. Procedure Material Diameter [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) Standard GMAW / pulse...
  • Page 88 Appendix JOB list JOB no. Procedure Material Diameter [mm] Cladding NiCr 6625 / 2.4831 Ar-78 / He-20 / CO2-2 (M12) Cladding NiCr 6625 / 2.4831 Ar-78 / He-20 / CO2-2 (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 89 Appendix JOB list JOB no. Procedure Material Diameter [mm] coldArc / coldArc puls CrNi 19 12 3 / 1.4430 Ar-97.5 / CO2-2.5 (M12) coldArc / coldArc puls CrNi 22 9 3 / 1.4462 / Ar-97.5 / CO2-2.5 (M12) Duplex coldArc / coldArc puls CrNi 22 9 3 / 1.4462 / Ar-97.5 / CO2-2.5 (M12) Duplex...

  • Page 90: Parameter Overview - Setting Ranges

    Appendix Parameter overview – setting ranges JOB no. Procedure Material Diameter [mm] React Speed RCC / React Speed RCC puls AlSi Ar-100 (I1) React Speed RCC / React Speed RCC puls AlSi Ar-100 (I1) React Speed RCC / React Speed RCC puls NiCr 6625 / 2.4831 Ar-70 / He-30 (I3) React Speed RCC / React...

  • Page 91: 11.2.2 Tig Welding

    Appendix Parameter overview – setting ranges 11.2.2 TIG welding Name Display Setting range Gas pre-flow duration Welding current start Start duration 0,00 20,0 Slope time start 0,00 20,0 Welding current A, depending on the power source max. Duration A 0,00 20,0 Slope time A ->...

  • Page 92: Searching For A Dealer

    Appendix Searching for a dealer 11.3 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-00L20M-EW501 28.01.2025...

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