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Summary of Contents for EWM comfyTig 18-1 CW
- Page 1 Operating instructions welding torch comfyTig 18-1 CW comfyTig 18-1 HW 099-500142-EW501 Observe additional system documents! 16.10.2024...
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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
Overview of device types ..................... 15 4.1.1 TIG cold wire welding ................... 15 4.1.2 TIG hot wire welding ..................... 15 comfyTig 18-1 CW ....................... 16 comfyTig 18-1 HW ....................... 17 4.3.1 Wire feed angle ....................18 5 Design and function ........................19 General .......................... - Page 4 Shielding gas supply (shielding gas cylinder for welding machine) ........51 General accessories ......................51 List of tools ........................... 51 10 Replaceable parts ......................... 52 10.1 comfyTig 18-1 CW/HW ......................52 11 Circuit diagram ..........................54 11.1 comfyTig 18-1 CW/HW ......................54 12 Appendix ............................55 12.1 Average wire electrode usage .....................
- Page 5 Contents Notes on using these operating instructions 099-500142-EW501 16.10.2024...
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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 poiso- nous phosgene. • Ensure sufficient fresh air! •...
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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.
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Page 13: Intended Use
3.3.1 Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 3.3.2 Declaration of Conformity This product corresponds in its design and construction to the EU directives listed in the decla- ration. -
Page 14: Part Of The Complete Documentation
Intended use Documents which also apply 3.3.4 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 Description - Quick Overview
For hot wire welding 4.1.1 TIG cold wire welding comfyTig 18-1 CW Cold wire welding is a variant of TIG welding featuring mechanically fed filler material. With this process, cold welding wire is melted, without power, in the arc of a tungsten electrode. -
Page 16: Comfytig 18-1 Cw
Machine description – quick overview comfyTig 18-1 CW comfyTig 18-1 CW Figure 4-1 Item Symbol Description Wire guide tube Crown nut Wire feed angle Contact tip - wire guide Gas nozzle Torch neck 45° Torch body Torch trigger - BRT 2... -
Page 17: Comfytig 18-1 Hw
Machine description – quick overview comfyTig 18-1 HW comfyTig 18-1 HW Figure 4-2 Item Symbol Description Wire guide tube Hot wire current lead Crown nut Wire feed angle Contact tip - wire guide Gas nozzle Torch neck 45° Torch body Torch trigger - BRT 2 Wire control (start/stop) Torch trigger - BRT 1... -
Page 18: Wire Feed Angle
Machine description – quick overview comfyTig 18-1 HW 4.3.1 Wire feed angle Figure 4-3 Item Symbol Description Flexible wire feed angle (15°–41°) Fixed wire feed angles 30°/39°/42° 099-500142-EW501 16.10.2024... -
Page 19: Design And Function
Design and function General Design and function General WARNING Risk of injury from electrical voltage! Contact with live parts, e.g. power connections, can be fatal! • Observe the safety information on the first pages of the operating instructions! • Commissioning must be carried out by persons who are specifically trained in handling power sources! •... -
Page 20: Scope Of Delivery
Design and function Scope of delivery Read and observe the documentation to all system and accessory components! Scope of delivery The delivery is checked and packaged carefully before dispatch, however it is not possible to exclude the possibility of damage during transit. Receiving inspection •... -
Page 21: Welding Torch Cooling System
All information relates to the total hose package length of the complete welding system and presents exemplary configurations (of components of the EWM product portfolio with standard lengths). A straight kink-free installation is to be ensured, taking into account the max. delivery height. -
Page 22: Welding Torch Connection
Design and function Transport and installation 5.3.3 Welding torch connection Equipment damage due to improperly connected coolant pipes! If the coolant pipes are not properly connected or a gas-cooled welding torch is used, the coo- lant circuit is interrupted and equipment damage can occur. •... -
Page 23: Control Cable Pin Configuration
Design and function Transport and installation • Extend and lay out the torch hose package. • Insert the wire feed plug of the welding torch into the wire electrode connector and lock by turning to the right. • Push the cable plug for the welding current (TIG) onto the connection socket (TIG) and lock by turning to the right. -
Page 24: Equipment Recommendations
Design and function Equipment recommendations Equipment recommendations 1.5 x 4.0 Liner EWM Cu- Dinse Low-alloy 1.5 x 4.0 V-groove CrZr connector 2.0 x 4.0 1.5 x 4.0 Torch EWM Cu- Combined PA li- Medium-alloy 1.5 x 4.0 V-groove CrZr neck 2.0 x 4.0... - Page 25 Design and function Equipment recommendations Figure 5-3 Item Symbol Description V-groove U-groove Knurled V-groove Steel liner Wire feed nipple Equipment side – Dinse connector Equipment side – torch neck Connecting sleeve Combined liner Equipment side for steel liner or liner > see 5.4 chapter. 099-500142-EW501 16.10.2024...
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Page 26: Convert Welding Torch
Design and function Convert welding torch Convert welding torch Figure 5-4 Item Symbol Description Gas nozzle Gas diffuser Tungsten electrode Collet Plastic insulation Support plate Hexagon nut Filler wire guide Allen screw Stud bolts M4x10 L26MM SW7, - L36MM SW7, - L41MM SW7 •... -
Page 27: Assemble The Wire Guide
Design and function Assemble the wire guide Assemble the wire guide Depending on the wire electrode diameter or type, either a steel liner or liner with the correct inner diameter must be inserted in the torch! Recommendation: • Use a steel liner when welding hard, unalloyed wire electrodes (steel). •... -
Page 28: Guide Spiral
Design and function Assemble the wire guide 5.6.1 Guide spiral The welding torch shown is an example only. Depending on the type used, torches may vary. Figure 5-6 • Cut off the welding wire tip. • Loosen the crown nut of the jointing sleeve. •... - Page 29 Design and function Assemble the wire guide Figure 5-8 • Disconnect the torch connector from the wire feeding. • Unscrew the crown nut from the inlet tube. • Extend and lay out the torch hose package. • Pull out steel liner Figure 5-9 •...
- Page 30 Design and function Assemble the wire guide Figure 5-10 • Cut off the new steel liner so that it has a length of at least 250 mm. • Plug the insulating tube onto the new steel liner. • Plug the crown nut onto the new steel liner. •...
- Page 31 Design and function Assemble the wire guide Figure 5-12 Figure 5-13 • Insert the new steel liner into the jointing sleeve as far as it goes. • Tighten the crown nut by hand. Item Symbol Description Crown nut Connecting sleeve Welding wire Collet chuck Steel liner...
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Page 32: Plastic Liner
Design and function Assemble the wire guide 5.6.2 Plastic liner The welding torch shown is an example only. Depending on the type used, torches may vary. Figure 5-14 • Disconnect the torch connector from the wire feeding. • Cut off the welding wire tip. •... - Page 33 Design and function Assemble the wire guide Figure 5-16 • Remove the crown nut, collet chuck and insulating tube from the combined liner. • Extend and lay out the torch hose package. Figure 5-17 • Sharpen the new combined liner with a liner sharpener. •...
- Page 34 Design and function Assemble the wire guide Figure 5-18 • Cut off the new combined liner with a tube cutter to a length of 15 mm. • Manually screw the inlet guide onto the new combined liner. • Plug the crown nut onto the inlet guide and manually screw to the inlet tube. Figure 5-19 •...
- Page 35 Design and function Assemble the wire guide Figure 5-20 Figure 5-21 • Insert the new combined liner into the jointing sleeve as far as it goes. • Tighten the crown nut by hand. Item Symbol Description Crown nut Connecting sleeve Welding wire Collet chuck Combined liner...
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Page 36: Configuring The Welding Machine For Mechanical Arc Fusion Welding
Design and function Configuring the welding machine for mechanical arc fusion welding Configuring the welding machine for mechanical arc fusion welding The welding machine must be configured before commissioning for the first time for mechanical arc fu- sion welding (cold or hot wire welding). The basic settings are configured directly at the welding machine control. -
Page 37: Non-Latched Manual
Design and function Operating modes (functional sequences) 5.8.2 Non-latched Manual The welding machine (power source) must be set to operating mode “latched”. Figure 5-23 First cycle (current) • Press torch trigger 1 (BRT 1), the gas pre-flow time elapses. • HF ignition pulses jump from the tungsten electrode to the workpiece. -
Page 38: Latched Manual
Design and function Operating modes (functional sequences) 5.8.3 Latched manual Figure 5-24 This operating mode differs from non-latched operation in the following ways: • Wire feeding is started by pressing and releasing (tapping) BRT 2. • By tapping you can switch to the reduced wire feeding. •... -
Page 39: Non-Latched Automatic
Design and function Operating modes (functional sequences) 5.8.4 Non-latched automatic The welding current has to be set to a non-latched operating mode at the welding machine. Figure 5-25 First cycle (current) • Press torch trigger 1 (BRT 1) and keep pressed. •... -
Page 40: Latched Automatic
Design and function Operating modes (functional sequences) 5.8.5 Latched automatic The welding machine (power source) must be set to operating mode “latched”. Figure 5-26 1. cycle (current) • Press torch trigger 1 (BRT 1), the gas pre-flow time elapses. • HF ignition pulses jump from the tungsten electrode to the workpiece. -
Page 41: Tack Welding
Shielding gas continues to flow in the selected gas post-flow time. 5.8.7 superPuls The two functions superPulse and the superimposed forward/backward movement of the wire cannot be used simultaneously. The EWM superPuls function enables automatic switching between two operating points in a process. Figure 5-28 Display Setting/selection Switch on... - Page 42 Design and function Operating modes (functional sequences) Display Setting/selection Selects superPuls Switches function on or off. Switch off Switching off machine function 099-500142-EW501 16.10.2024...
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Page 43: 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 44: Maintenance And Care Before Each Use
Maintenance, care and disposal General Torch connection • The thread of the crown nut is dirty or damaged. • For water-cooled welding torches, also check the coolant connections for damage. Grip • Cracks, penetration Hose package • Cracks, penetration Figure 6-1 To prevent damage to and malfunction of the welding torch and hose package: •... -
Page 45: Regular Maintenance
Maintenance, care and disposal General 6.1.3 Regular maintenance The regular maintenance of a welding torch depends heavily on the duration of use and the stress and must be specified by the operator / owner. As a rule of thumb, every time the wire spool or wire basket is replaced or, if necessary, at a change of shift. -
Page 46: 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 47: Rectifying Faults
Rectifying faults Checklist for rectifying faults Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dea- ler. - Page 48 Rectifying faults Checklist for rectifying faults Wire feed problems Unsuitable or worn welding torch equipment Adjust contact tip (cold wire/hot wire) to wire diameter, blow through and replace if necessary Adjust wire guide to material in use, blow through and replace if necessary ...
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Page 49: Vent Coolant Circuit
Rectifying faults Vent coolant circuit Vent coolant circuit Figure 7-1 • Switch off the machine and fill the coolant tank to the maximum level. • Unlock the quick-connect coupling with a suitable tool (connection open). To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)! Figure 7-2 •... -
Page 50: Technical Data
Technical data comfyTig 18-1 CW/HW Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! comfyTig 18-1 CW/HW comfyTig 18-1 CW comfyTig 18-1 HW Welding torch polarity Normally negative (Direct voltage) Guide type Manually operated... -
Page 51: Accessories
Accessories Welding torch cooling system Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. Welding torch cooling system Type Designation Item no. HOSE BRIDGE UNI Tube bridge 092-007843-00000 LFMG HANNA DIST 3 Conductivity meter 094-026184-00000 9.1.1... -
Page 52: Replaceable Parts
Replaceable parts comfyTig 18-1 CW/HW Replaceable parts 10.1 comfyTig 18-1 CW/HW The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode hold- ers, remote controls, spare parts and replacement parts, etc.) from our range of products! •... - Page 53 Replaceable parts comfyTig 18-1 CW/HW Item Order number Type Designation 094-001195-00000 GNDIF TIG 17/18/26/18SC 11x47mm Gas nozzle for gas lens 094-001196-00000 GNDIF TIG 17/18/26/18SC 12.5x47mm Gas nozzle for gas lens 094-001320-00000 GNDIF TIG 17/18/26/18SC 6.5x42mm Gas nozzle for gas lens...
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Page 54: Circuit Diagram
Circuit diagram comfyTig 18-1 CW/HW Circuit diagram 11.1 comfyTig 18-1 CW/HW The circuit diagrams are only intended for authorised service personnel! Figure 11-1 099-500142-EW501 16.10.2024... -
Page 55: Appendix
Appendix Average wire electrode usage Appendix 12.1 Average wire electrode usage 5 m/min – 197 ipm inch .040 .045 .060 Steel kg/h 10.3 lb/h Stainless steel 10.5 Aluminium 10 m/min – 394 ipm Steel kg/h 11.6 20.9 lb/h Stainless steel 11.9 21.1 Aluminium... -
Page 56: Searching For A Dealer
Appendix Searching for a dealer 12.3 Searching for a dealer Sales & service partners www.ewm-group.com/en/specialist-dealers "More than 400 EWM sales partners worldwide" 099-500142-EW501 16.10.2024...
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