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Operating instructions
Wire feed unit
Phoenix Expert drive 4L M3.70
099-004846-EW501 Observe additional system documents! 8.01.2014
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General instructions
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read the operating instructions for all system components!
• Observe accident prevention regulations!
• Observe all local regulations!
• Confirm with a signature where appropriate.
NOTE
In the event of queries on installation, commissioning, operation or special conditions at the installation site, or on usage, please contact your sales partner or our customer service department on +49 2680 181-0.
A list of authorised sales partners can be found at www.ewm-group.com.
Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result. For this reason, we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation, improper operation or incorrect usage and maintenance or any actions connected to this in any way.
© EWM AG · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, including extracts, only permitted with written approval.
Subject to technical amendments.
Contents
Notes on the use of these operating instructions
1 Contents
Open the protective flap of the wire feeder ................................................... 32
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Contents
Notes on the use of these operating instructions
Operating point setting using material thickness .......................................... 40
Accessory components for operating point setting ....................................... 41
Conventional MIG/MAG Welding (GMAW non synergic) ............................................. 42
Setting the operating point (welding output).................................................. 42
MIG/MAG program sequence ("Program steps" mode) ............................................... 45
MIG/MAG overview of parameters, M3.70 .................................................... 46
Program- and Up- / down operation .............................................................. 48
MIG/MAG Push/Pull welding torch ................................................................ 49
Switching between Push/Pull and intermediate drive ................................... 50
Setting using the stick electrode diameter .................................................... 60
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Contents
Notes on the use of these operating instructions
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Safety instructions
Notes on the use of these operating instructions
2 Safety instructions
2.1
Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general warning symbol.
• The risk is explained using a symbol on the edge of the page.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general warning symbol.
• The hazard is explained using a symbol at the edge of the page.
NOTE
Special technical points which users must observe.
• Notes include the "NOTE" keyword in the heading without a general warning symbol.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.
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Safety instructions
Explanation of icons
2.2
Explanation of icons
Symbol Description
Press
Do not press
Turn
Switch
Switch off machine
Switch on machine
ENTER (enter the menu)
NAVIGATION NAVIGATION (Navigating in the menu)
4 s
EXIT EXIT (Exit the menu)
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use
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Safety instructions
General
2.3
General
DANGER
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers.
• Observe the maintenance instructions! (see Maintenance and Testing chapter)
• Unwind welding leads completely!
• Shield devices or equipment sensitive to radiation accordingly!
• The correct functioning of pacemakers may be affected (obtain advice from a doctor if necessary).
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Electric shock!
Welding machines use high voltages which can result in potentially fatal electric shocks and burns on contact. Even low voltages can cause you to get a shock and lead to accidents.
• Do not touch any live parts in or on the machine!
• Connection cables and leads must be free of faults!
• Switching off alone is not sufficient!
• Place welding torch and stick electrode holder on an insulated surface!
• The unit should only be opened by specialist staff after the mains plug has been unplugged!
• Only wear dry protective clothing!
• Wait for 4 minutes until the capacitors have discharged!
WARNING
Validity of this document!
This document is only valid in combination with the operating instructions for the power source being used (welding machine)!
• Read the operating instructions, in particular the safety instructions for the power source
(welding machine)!
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
Explosion risk!
Apparently harmless substances in closed containers may generate excessive pressure when heated.
• Move containers with inflammable or explosive liquids away from the working area!
• Never heat explosive liquids, dusts or gases by welding or cutting!
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Safety instructions
General
WARNING
Risk of injury due to radiation or heat!
Arc radiation results in injury to skin and eyes.
Contact with hot workpieces and sparks results in burns.
• Use welding shield or welding helmet with the appropriate safety level (depending on the application)!
• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant regulations in the country in question!
• Protect persons not involved in the work against arc beams and the risk of glare using safety curtains!
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!
• Ensure that there is sufficient fresh air!
• Keep solvent vapour away from the arc beam field!
• Wear suitable breathing apparatus if appropriate!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts and hot slag produced during the welding process.
Stray welding currents can also result in flames forming!
• Check for fire hazards in the working area!
• Do not carry any easily flammable objects such as matches or lighters.
• Keep appropriate fire extinguishing equipment to hand in the working area!
• Thoroughly remove any residue of flammable substances from the workpiece before starting welding.
• Only continue work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
• Connect welding leads correctly!
Danger when coupling multiple power sources !
Coupling multiple power sources in parallel or in series has to be carried out by qualified personnel and in accordance with the manufacturer's guidelines. Before bringing the power sources into service for arc welding operations, a test has to verify that they cannot exceed the maximum allowed open circuit voltage.
• Connection of the machine may be carried out by qualified personnel only!
• When decommissioning individual power sources, all mains and welding current leads have to be safely disconnected from the welding system as a whole. (Danger due to inverse voltages
!
)
• Do not couple welding machines with pole reversing switch (PWS series) or machines for
AC welding, as a minor error in operation can cause the welding voltages to be combined.
CAUTION
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
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Safety instructions
General
Obligations of the operator!
CAUTION
The respective national directives and laws must be observed for operation of the machine!
• National implementation of the framework directive (89/391/EWG), as well as the associated individual directives.
• In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work.
• The regulations regarding work safety and accident prevention for the respective country.
• Setting up and operating the machine according to IEC 60974-9.
• Check at regular intervals that users are working in a safety-conscious way.
• Regular checks of the machine according to IEC 60974-4.
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.
Damage to the machine due to stray welding currents!
Stray welding currents can destroy protective earth conductors, damage equipment and electronic devices and cause overheating of components leading to fire.
• Make sure all welding leads are securely connected and check regularly.
• Always ensure a proper and secure electrical connection to the workpiece!
• Set up, attach or suspend all conductive power source components like casing, transport vehicle and crane frames so they are insulated!
• Do not place any other electronic devices such as drillers or angle grinders, etc., on the power source, transport vehicle or crane frames unless they are insulated!
• Always put welding torches and electrode holders on an insulated surface when they are not in use!
Mains connection
Requirements for connection to the public mains network
High-performance machines can influence the mains quality by taking current from the mains network. For some types of machines, connection restrictions or requirements relating to the maximum possible line impedance or the necessary minimum supply capacity at the interface with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect, attention is also drawn to the machines' technical data. In this case, it is the responsibility of the operator, where necessary in consultation with the mains network operator, to ensure that the machine can be connected.
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Safety instructions
General
CAUTION
EMC Machine Classification
In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data):
Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network. When ensuring the electromagnetic compatibility of class A machines, difficulties can arise in these areas due to interference not only in the supply lines but also in the form of radiated interference.
Class B machines fulfil the EMC requirements in industrial as well as residential areas, including residential areas connected to the low-voltage public mains network.
Setting up and operating
When operating arc welding systems, in some cases, electro-magnetic interference can occur although all of the welding machines comply with the emission limits specified in the standard.
The user is responsible for any interference caused by welding.
In order to evaluate any possible problems with electromagnetic compatibility in the surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)
• Mains, control, signal and telecommunication lines
• Radios and televisions
• Computers and other control systems
• Safety equipment
• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing aid
• Calibration and measuring equipment
• The immunity to interference of other equipment in the surrounding area
• The time of day at which the welding work must be carried out
Recommendations for reducing interference emission
• Mains connection, e.g. additional mains filter or shielding with a metal tube
• Maintenance of the arc welding equipment
• Welding leads should be as short as possible and run closely together along the ground
• Potential equalization
• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly, it should be connected by means of suitable capacitors.
• Shielding from other equipment in the surrounding area or the entire welding system
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Safety instructions
Transport and installation
2.4
Transport and installation
WARNING
Incorrect handling of shielding gas cylinders!
Incorrect handling of shielding gas cylinders can result in serious and even fatal injury.
• Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air!
• Place shielding gas cylinders in the holders provided for them and secure with fixing devices.
• Avoid heating the shielding gas cylinder!
Risk of accident due to improper transport of machines that may not be lifted!
Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only!
• The machine may not be lifted by crane or suspended!
CAUTION
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up. Tilt resistance is guaranteed up to an angle of 10°
(according to IEC 60974-1).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads, control leads, etc.) may cause hazards such as connected equipment tipping over and injuring persons!
• Disconnect supply lines!
CAUTION
Equipment damage when not operated in an upright position!
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
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Safety instructions
Transport and installation
2.4.1
Ambient conditions
CAUTION
Installation site!
The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base!
• The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work.
• Safe operation of the machine must be guaranteed at all times.
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
• Avoid ambient air containing salt (sea air)!
Non-permissible ambient conditions!
Insufficient ventilation results in a reduction in performance and equipment damage.
• Observe the ambient conditions!
• Keep the cooling air inlet and outlet clear!
• Observe the minimum distance of 0.5 m from obstacles!
2.4.1.1
In operation
Temperature range of the ambient air:
• -25 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
2.4.1.2
Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -30 °C to +70 °C
Relative air humidity
• Up to 90% at 20 °C
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Intended use
Applications
3 Intended use
WARNING
Hazards due to improper usage!
Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage!
• The equipment must only be used in line with proper usage and by trained or expert staff!
• Do not modify or convert the equipment improperly!
3.1
Applications
3.1.1
MIG/MAG standard welding
Metal arc welding using a wire electrode whereby gas from an external source surrounds the arc and the molten pool to protect them from the atmosphere.
3.1.1.1
forceArc
Heat-reduced, directionally stable and powerful arc with deep penetration for the higher performance range. Non-alloyed, low-alloy and high-alloy steels and high-tensile fine-grained steels
3.1.1.2
rootArc
Short arc with perfect weld modelling capabilities for effortless gap bridging and positional welding
3.1.2
MIG/MAG pulse welding
Welding process for optimum welding results when joining stainless steel and aluminium thanks to controlled drop transfer and targeted, adapted heat input.
3.1.2.1
forceArc puls
Effective addition to the forceArc arc, perfect for welding final passes in all performance classes and all positions.
3.1.2.2
rootArc puls
The perfect enhancement for focused heat input for the higher performance range
3.1.3
TIG (Liftarc) welding
TIG welding process with arc ignition by means of workpiece contact.
3.1.4
MMA welding
Manual arc welding or, for short, MMA welding. It is characterised by the fact that the arc burns between a melting electrode and the molten pool. There is no external protection; any protection against the atmosphere comes from the electrode.
3.1.4.1
Air arc gouging
During air arc gouging, bad welding seams are heated with a carbon electrode and then removed with compressed air. Special electrode holders and carbon electrodes are required for air arc gouging.
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Intended use
Use and operation solely with the following machines
3.2
Use and operation solely with the following machines
NOTE
A suitable power source (system component) is required in order to operate the wire feed unit!
Phoenix Expert drive 200C drive 300C drive 4L M3.70 drive 4 M3.70 miniDrive
351, 401, 451, 551
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Intended use
Documents which also apply
3.3
Documents which also apply
3.3.1
Warranty
NOTE
For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"!
3.3.2
Declaration of Conformity
The designated machine conforms to EC Directives and standards in terms of its design and construction:
• EC Low Voltage Directive (2006/95/EC),
• EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised modifications, improperly conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted conversion work not specifically authorised by the manufacturer.
The original copy of the declaration of conformity is enclosed with the unit.
3.3.3
Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in environments with an increased electrical hazard.
3.3.4
Service documents (spare parts and circuit diagrams)
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.3.5
Calibration/Validation
We hereby confirm that this machine has been tested using calibrated measuring equipment, as stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances.
Recommended calibration interval: 12 months
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Machine description
– quick overview
Front view
4 Machine description – quick overview
4.1
Front view
Figure 4-1
Item Symbol Description 0
1 Carrying handle
2 Wire spool casing
3
4
5
6
7
8
9
10
Protective cap
Cover for the wire feed mechanism and other operating elements.
Depending on the machine series, additional stickers with information on the replacement parts and JOB lists will be located on the inside.
Welding torch connection (Euro or Dinse torch connector)
Welding current, shielding gas and torch trigger integrated
Slide latch, lock for the protective cap
7-pole connection socket (digital)
For connecting digital accessory components (remote control, welding torch control lead, etc.)
19-pole connection socket (analogue)
For connecting analogue accessory components (remote control, welding torch control lead, etc.)
Quick connect coupling (blue) coolant supply
Quick connect coupling (red) coolant return
Machine control
See Machine control – operating elements chapter
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Machine description
– quick overview
Rear view
4.2
Rear view
18
Figure 4-2
6
7
8
Item Symbol Description 0
1 7-pole connection socket (digital)
• Control lead for wire feed unit
2 Connecting nipple G¼, shielding gas connection
3
4
5
9
Quick connect coupling (red) coolant return
Connector plug, welding current "+"
Welding current connection on wire feed unit
Quick connect coupling (blue) coolant supply
Machine feet
Intermediate hose package strain relief
Take up point
For housing arbor, wire feed unit
Wire spool casing
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4.3
Inside view
Machine description
– quick overview
Inside view
Figure 4-3
Item Symbol Description 0
1 Wire spool casing
2 Wire spool holder
3
4
Take up point
For housing arbor, wire feed unit
Wire feed unit
5
6
Welding torch function changeover switch (special welding torch required)
Changing over programs or JOBs
Protective cap
Infinite adjustment of welding performance.
Cover for the wire feed mechanism and other operating elements.
Depending on the machine series, additional stickers with information on the replacement parts and JOB lists will be located on the inside.
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Machine description
– quick overview
Machine control – Operating elements
4.4
Machine control – Operating elements
20
Figure 4-4
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Machine description
– quick overview
Machine control – Operating elements
Item Symbol Description 0
1 Lid (see chap. "Machine control – concealed operating elements")
2
3
4
Push-button, parameter selection left/power-saving mode
Welding current
Material thickness
Wire feed speed
After welding, the values used last are shown from the main program. The signal light is illuminated.
Enter power-saving mode by pressing the push-button for a longer time.
Display, left
Welding current, material thickness, wire speed, hold values
Welding parameter setting, rotary dial
For setting the welding performance and for setting other welding parameters.
5
6
Select operating mode button
Non-latched
Latched
Signal light lights up in green: Special non-latched
Signal light lights up in red: MIG spot welding
Special latched
Dynamics/choke effect button
Arc harder and narrower
7
8
9
10
Arc softer and wider
Button, Select welding type
MIG/MAG standard welding
MIG/MAG pulse arc welding
Arc length correction/selection of welding program, rotary dial
• Correction of the arc length from -9.9 V to +9.9 V.
• Selection of welding programs 0 to 15 (not possible if accessory components, such as program torches, are connected).
Display, right
Welding voltage, program number
Button, Parameter selection (right)
VOLT Welding voltage
PROG Program number kW Welding performance display
Gas flow quantity (optional)
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Machine description
– quick overview
Machine control – Operating elements
4.4.1
Machine control
– Concealed operating elements
22
Figure 4-5
Item Symbol Description 0
1 Select welding parameters button
This button is used to select the welding parameters depending on the welding process and operating mode used.
2 Signal light, gas pre-flow time
Setting range 0.0 s to 20.0 s
3
4
5
Signal light, start program (P
START
)
• Wire speed:1% to 200% of the main program P
A
• Correction of the arc length -9.9 V to +9.9 V
Signal light, start time
Setting range, absolute 0.0 s to 20.0 s (0.1 s increments)
Signal light, slope time program P
START
to main program P
A
Setting range 0.0 s to 20.0 s (0.1 s increments)
6
7
8
9
Signal light, main program (P
A
)
• Wire speed WF-min. to WF-max.
• Correction of the arc length -9.9 V to +9.9 V
Signal light, dynamics
Setting range -40 to +40
Signal light, duration of main program P
A
Setting range 0.1 s to 20.0 s (0.1 s increments).
Used e.g. in connection with the super pulse function
Signal light, reduced main program (P
B
)
• Wire speed:1% to 200% of the main program P
A
• Correction of the arc length -9.9 V to +9.9 V
10
11
12
13
14
Signal light, duration reduced main program P
B
Setting range 0.0 s to 20.0 s (0.1 s increments).
Used e.g. in connection with the super pulse function.
Signal light, slope time program P
A
(or P
B
) to end program P
END
Setting range 0.0 s to 20.0 s (0.1 s increments)
Signal light, end program (P
END
)
• Wire speed:1% to 200% of the main program P
A
• Correction of the arc length -9.9 V to +9.9 V
Signal light, duration of end program P
END
Setting range 0.0 s to 20.0 s (0.1 s increments)
Signal light, gas post-flow time
Setting range 0.0 s to 20.0 s
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Machine description
– quick overview
Machine control – Operating elements
Item Symbol Description 0
15
16
Signal lamp, super pulse function
Lights up when the super pulse function is active.
Button, special job
Select the special jobs SP1 to SP3 (JOB 129 to 131)
17 Wire inching button
See also “Inching the Wire Electrode” chapter
18 Gas test / rinse button
• Gas test:
• Rinse:
For setting the shielding gas quantity
For rinsing longer hose packages
See also "Shielding Gas Supply" chapter
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Design and function
General
5 Design and function
5.1
General
WARNING
Risk of injury from electric shock!
Contact with live parts, e.g. welding current sockets, is potentially fatal!
• Follow safety instructions on the opening pages of the operating instructions.
• Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines!
• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead, interfaces) may only be connected when the machine is switched off!
CAUTION
Insulate the arc welder from welding voltage!
Not all active parts of the welding current circuit can be shielded from direct contact. To avoid any associated risks it is vital for the welder to adhere to the relevant safety regulations. Even low voltages can cause a shock and lead to accidents.
• Wear dry and undamaged protective clothing (shoes with rubber soles/welder's gloves made from leather without any studs or braces)!
• Avoid direct contact with non-insulated connection sockets or connectors!
• Always place torches and electrode holders on an insulated surface!
Risk of burns on the welding current connection!
If the welding current connections are not locked, connections and leads heat up and can cause burns, if touched!
• Check the welding current connections every day and lock by turning in clockwise direction, if necessary.
Risk of injury due to moving parts!
The wire feeders are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons!
• Do not reach into rotating or moving parts or drive components!
• Keep casing covers or protective caps closed during operation!
Risk of injury due to welding wire escaping in an unpredictable manner!
Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may escape in an uncontrolled manner and injure persons!
• Before mains connection, set up the complete wire guide system from the wire spool to the welding torch!
• Remove the pressure rollers from the wire feeder if no welding torch is fitted!
• Check wire guide at regular intervals!
• Keep all casing covers or protective caps closed during operation!
Risk from electrical current!
If welding is carried out alternately using different methods and if a welding torch and an electrode holder remain connected to the machine, the open-circuit/welding voltage is applied simultaneously on all cables.
• The torch and the electrode holder should therefore always be placed on an insulated surface before starting work and during breaks.
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Design and function
Installation
CAUTION
Damage due to incorrect connection!
Accessory components and the power source itself can be damaged by incorrect connection!
• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.
• Comprehensive descriptions can be found in the operating instructions for the relevant accessory components.
• Accessory components are detected automatically after the power source is switched on.
Using protective dust caps!
Protective dust caps protect the connection sockets and therefore the machine against dirt and damage.
• The protective dust cap must be fitted if there is no accessory component being operated on that connection.
• The cap must be replaced if faulty or if lost!
NOTE
Observe documentation of other system components when connecting!
5.2
Installation
WARNING
Risk of accident due to improper transport of machines that may not be lifted!
Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only!
• The machine may not be lifted by crane or suspended!
• Depending on machine type, equipment for lifting by crane or use while suspended is available as a retrofitting option (see chapter "Accessories").
CAUTION
Installation site!
The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base!
• The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work.
• Safe operation of the machine must be guaranteed at all times.
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Design and function
Welding torch cooling system
5.3
Welding torch cooling system
5.3.1
General
Coolant mixtures!
CAUTION
Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void!
• Only use the coolant described in this manual (overview of coolants).
• Do not mix different coolants.
• When changing the coolant, the entire volume of liquid must be changed.
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding torch (see overview of coolants).
Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components.
• The coolant must be checked for adequate frost protection with the TYP 1 frost protection tester (see accessories).
• Replace coolant as necessary if frost protection is inadequate!
NOTE
The disposal of coolant must be carried out according to official regulations and observing the relevant safety data sheets (German waste code number: 70104)!
• Coolant must not be disposed of together with household waste.
• Coolant must not be discharged into the sewerage system.
• Recommended cleaning agent: water, if necessary with cleaning agent added.
5.3.2
List of coolants
The following coolants may be used (for item nos., please see the Accessories chapter):
Coolant
KF 23E (Standard)
Temperature range
-10 °C to +40 °C
KF 37E -20 °C to +10 °C
DKF 23E (for plasma machines) 0 °C to +40 °C
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Notes on the installation of welding current leads
5.4
Notes on the installation of welding current leads
NOTE
Incorrectly installed welding current leads can cause faults in the arc (flickering).
A Install welding lead and hose package in parallel and as close together as possible.
B Keep the welding lead and hose packages of each welding machine separate, with an installation distance of at least 15 cm!
C Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops!
D Use an individual welding lead to the workpiece for each welding machine!
Connect the work clamp close to the welding point.
E Always keep leads as short as possible!
Item Symbol Description 0
1 Welding machine
2 Wire feed unit
3 Workpiece
Figure 5-1
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Intermediate hose package connection
5.5
Intermediate hose package connection
Figure 5-2
Item Symbol Description 0
1 Power source
2 Intermediate hose package
3 7-pole connection socket (digital)
• Control lead for wire feed unit
4 Connecting nipple G¼, shielding gas connection
5
6
7
8
Quick connect coupling (red) coolant return
Connector plug, welding current "+"
Welding current connection on wire feed unit
Quick connect coupling (blue) coolant supply
Intermediate hose package strain relief
• Insert the end of the hose package through the strain relief of the hose package and lock by turning to the right.
• Push the welding current cable socket onto the “welding current connecting plug” and lock by turning to the right.
• Connect crown nut of the shielding gas line to the G¼“ connecting nipple.
• Insert cable plug on the control lead into the 7-pole connection socket and secure with crown nut (the plug can only be inserted into the connection socket in one position).
• Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings:
Return line red to quick connect coupling, red (coolant return) and supply line blue to quick connect coupling, blue (coolant supply).
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Shielding gas supply (shielding gas cylinder for welding machine)
5.6
Shielding gas supply (shielding gas cylinder for welding machine)
5.6.1
Gas test
• Slowly open the gas cylinder valve.
• Open the pressure regulator.
• Switch on the power source at the main switch.
• Initiate gas test function on the machine control.
• Set the relevant gas quantity for the application on the pressure regulator.
• The gas test is triggered on the machine control by pressing the button briefly.
Shielding gas flows for around 25 seconds or until the button is pressed again.
5.6.2
“Rinse hose package” function
Operating
Element
Action Result
5 s
Select rinse hose package.
Shielding gas flows continuously until the Gas Test button is pressed again.
5.6.3
Setting the shielding gas quantity
Welding process Recommended shielding gas quantity
MAG welding
MIG brazing
MIG welding (aluminium)
Wire diameter x 11.5 = l/min
Wire diameter x 11.5 = l/min
Wire diameter x 13.5 = l/min (100 % argon)
Helium-rich gas mixtures require a higher gas volume!
The table below can be used to correct the gas volume calculated where necessary:
Shielding gas
75% Ar/25% He
50% Ar/50% He
25% Ar/75% He
100% He
Factor
1.14
1.35
1.75
3.16
NOTE
Incorrect shielding gas setting!
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.
• Adjust the shielding gas quantity to suit the welding task!
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5.7
MIG/MAG welding
5.7.1
Welding torch connection
CAUTION
Equipment damage due to improperly connected coolant lines!
If the coolant lines are not connected or a gas-cooled welding torch is used, the coolant circuit is interrupted and equipment damage can occur.
• Connect all coolant lines correctly!
• When using a gas-cooled welding torch, add a tube bridge to the coolant circuit (see chapter “Accessories”).
NOTE
Fault with the wire guide!
On delivery, the central connector is fitted with a capillary tube for welding torches with spiral guides. Conversion is necessary if a welding torch with a plastic core is used!
Welding torch with plastic core:
• use with guide tube!
Welding torch with spiral guide:
• use with capillary tube!
Depending on the wire electrode diameter or type, either a spiral guide or plastic core with the correct inner diameter has to be inserted in the torch!
Recommendation:
• Use a spiral guide to weld hard, unalloyed wire electrodes (steel).
• Use a plastic core to weld or braze soft, high-alloy wire electrodes or aluminium materials.
Preparation for connecting welding torches with a plastic core:
• Push forward the capillary tube on the wire feed side in the direction of the central connector and remove it there.
• Slide plastic core guide tube off the central connector.
• Carefully insert the central plug for the welding torch, with the still oversized plastic liner, into the central connector and screw together with crown nut.
• Use a suitable tool to cut off the plastic liner just before the wire feed roller, making sure not to pinch it.
• Unfasten and remove the central plug on the welding torch.
• Cleanly remove the burr from the separated end of the plastic core!
Preparation for connecting welding torches with a spiral guide:
• Check that the capillary tube is correctly positioned in relation to the central connector!
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Figure 5-3
Item Symbol Description 0
1 Welding torch
2
3
4
5
6
Welding torch hose package
Welding torch connection (Euro or Dinse torch connector)
Welding current, shielding gas and torch trigger integrated
19-pole connection socket (analogue)
For connecting analogue accessory components (remote control, welding torch control lead, etc.)
Quick connect coupling (blue) coolant supply
Quick connect coupling (red) coolant return
• Insert the central plug for the welding torch into the central connector and screw together with crown nut.
• Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings:
Return line red to quick connect coupling, red (coolant return) and supply line blue to quick connect coupling, blue (coolant supply).
Only MIG/MAG torches with special functions (additional control lead):
• Insert the torch control lead plug into the 19-pole connection socket and lock in place.
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5.7.2
Wire feed
5.7.2.1
Open the protective flap of the wire feeder
CAUTION
To perform the following steps, the protective flap of the wire feeder needs to be opened. Make sure to close the protective flap again before starting to work.
• Unlock and open protective flap.
5.7.2.2
Inserting the wire spool
CAUTION
Risk of injury due to incorrectly secured wire spool.
If the wire spool is not secured properly, it may come loose from the wire spool holder and fall to the ground, causing damage to the machine and injuries.
• Securely fasten the wire spool to the wire spool holder using the knurled nut.
• Before you start working, always check the wire spool is securely fastened.
NOTE
Standard D300 wire spool holder can be used. Adapters (see accessories) are required when using standardised basket coils (DIN 8559).
Figure 5-4
Item Symbol Description 0
1
2
Carrier pin
For fixing the wire spool
Knurled nut
For fixing the wire spool
• Loosen knurled nut from spool holder.
• Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore.
• Fasten wire spool using knurled nut.
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5.7.2.3
Changing the wire feed rollers
NOTE
Unsatisfactory welding results due to faulty wire feeding!
Wire feed rollers must be suitable for the diameter of the wire and the material.
• Check the roller label to verify that the rollers are suitable for the wire diameter.
Turn or change if necessary!
• use V-groove rollers with for steel wires and other hard wires,
• use U-groove rollers for aluminium wires and other soft, alloyed wires.
• Slide new drive rollers into place so that the diameter of the wire used is visible on the drive roller.
• Screw the drive rollers in place with knurled screws.
Figure 5-5
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5.7.2.4
Inching the wire electrode
CAUTION
Risk of injury due to moving parts!
The wire feeders are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons!
• Do not reach into rotating or moving parts or drive components!
• Keep casing covers or protective caps closed during operation!
Risk of injury due to welding wire escaping in an unpredictable manner!
Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may escape in an uncontrolled manner and injure persons!
• Before mains connection, set up the complete wire guide system from the wire spool to the welding torch!
• Remove the pressure rollers from the wire feeder if no welding torch is fitted!
• Check wire guide at regular intervals!
• Keep all casing covers or protective caps closed during operation!
Risk of injury due to welding wire escaping from the welding torch!
The welding wire can escape from the welding torch at high speed and cause bodily injury including injuries to the face and eyes!
• Never direct the welding torch towards your own body or towards other persons!
CAUTION
Extensive wear due to incorrect contact pressure!
Incorrect contact pressure will cause extensive wear of the wire feed rollers!
• With the adjusting nuts of the pressure units set the contact pressure so that the wire electrode is conveyed but will still slip through if the wire spool jams.
• Set the contact pressure of the front rollers (in wire feed direction) to a higher value!
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Figure 5-6
Item Symbol Description 0
1 Pressure unit
2 Clamping unit
3 Knurled nut
4 Pressure roller
5 Wire feed nipple
6 Guide tube
7 Drive rollers
8 "Undetachable" knurled screws
9 Wire feed nipple with wire stabiliser
• Extend and lay out the torch hose package.
• Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip upwards).
• Unwind welding wire carefully from the wire spool and insert through the wire inlet nipple over the drive roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe.
• Press the clamping element with the pressure roller back downwards and fold the wire units back up again (wire electrode should be in the groove on the drive roller).
• Set the contact pressure with the adjusting nuts of the pressure unit.
• Press the wire inching button until the wire electrode projects out of the welding torch.
Automatic inching stop
Touch the welding torch against the workpiece during inching. Inching of the welding wire will stop as soon it touches the workpiece.
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5.7.2.5
Spool brake setting
Figure 5-7
Item Symbol Description 0
1 Allen screw
Securing the wire spool retainer and adjustment of the spool brake
• Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect.
NOTE
Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation!
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5.7.3
Definition of MIG/MAG welding tasks
This machine range features simple operation with a very wide range of functions.
• Various JOBs (i.e. welding tasks consisting of welding process, material type, wire diameter and shielding gas type) have been pre-defined (see appendix for a list of JOBs).
• Simple JOB selection using four buttons (material, wire type, wire thickness and shielding gas) on the welding machine control; illogical combinations are automatically excluded.
• The required process parameters are calculated by the system depending on the operating point defined (single-dial operation via wire speed rotary dial).
• Additional parameters can be modified as required in the configuration menu on the control or using the PC300.NET welding parameter software.
5.7.4
Welding task selection
NOTE
Selection of a welding task involves the interaction of the controls on the welding machine and the wire feed unit. After the basic settings are made on the welding machine, the operating point and other parameters can be set on the wire feed unit.
It is only possible to change the 4 basic welding parameters if:
• No welding current is flowing,
• The key switch is set to position "1".
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Superpuls
Superpul s m /m in
D Y N m /m in
Figure 5-8
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Design and function
MIG/MAG welding
Operating element
Action Result n x n x n x n x n x n x
1 x
Select welding process
The signal light indicates the selection.
Select material type
The signal light indicates the selection.
Select wire diameter
The signal light indicates the selection.
Select gas type
The signal light indicates the selection.
Select operating mode
The LED displays the selected operating mode.
Non-latched operation
Latched operation
Green Special non-latched mode
Red Spot operating mode
Special latched mode
Select welding type
The signal light indicates the selection.
Standard MIG/MAG welding
Pulse arc MIG/MAG welding
Switch superpulses on or off
The signal light indicates the selection.
Operating point is set using the wire speed previously set
Arc length correction setting
Select Dynamics welding parameter
Dynamic comes on.
Dynamics setting
Arc harder and narrower
Arc softer and wider
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5.7.4.1
Burn-back
NOTE
Prevents fusing of the wire electrode in the weld pool.
Back-burn set too high:
• Large ball formation of the wire electrode (poor re-ignition)
• Wire electrode sticks in the gas nozzle.
Back-burn set too low:
• Wire electrode sticks in the weld pool.
Welding machine
Operating element
Action Result
Select program sequence mode
1 x
Select "RUECK" parameter using the "Up" n x and "Down" buttons (left)
Display
Program steps
RUECK 2-500
Adjust the selected parameter using the "Up"
RUECK 2-500 n x and "Down" buttons (right)
Machine returns to Display mode
3 x
Wire feed unit
ENTER EXIT
3 s
3 s m /m in
Figure 5-9
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5.7.5
MIG/MAG operating point
The operating point (welding output) is specified using the principle of MIG/MAG one-dial operation, i.e. the user need only specify the operating point by setting the required wire speed, for example, and the digital system will calculate the optimum values for welding current and voltage (operating point).
The operating point setting can also be specified using the accessory components such as the remote control, welding torch, etc.
5.7.5.1
Selecting the display unit
The operating point (welding performance) can be displayed as the welding current, material thickness or wire speed.
On the welding machine using control M3.19
Operating element
Action Result n x
Switching the display between:
Welding current,
Material thickness,
Wire speed
On the wire feed unit using control M3.70
Operating element
Action Result n x
Switching the display between:
Welding current
Material thickness,
Wire speed
Example application
You are welding aluminium (material= AlMg, gas= Ar 100%, wire diameter= 1.2 mm and 5 mm material thickness), you don’t have any specifications and do not know the required settings, e.g. for the wire speed.
Switch to the material thickness display. Set the operating point to 5 mm.
This corresponds to a wire speed of 8.4 m/min, for example.
5.7.5.2
Operating point setting using material thickness
NOTE
The settings are made on the wire feed unit control.
The process of setting the operating point by means of the panel thickness parameter is described as an example below.
Operating element
Action Result Display
Increase or reduce welding performance via the panel thickness parameter.
Display example: 5.0 mm
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5.7.5.3
Arc length correction setting
NOTE
The settings are made on the wire feed unit control.
Operating
Element
Action Result
Arc length correction setting
Display
Parameter selected is displayed
5.7.5.4
Accessory components for operating point setting
The operating point can also be set with various accessory components such as
• remote controls
• special torches
• PC software
• robot and industrial bus interfaces (optional mechanised welding interface required – not possible for all machines in this series!)
You will find an overview of accessory components in the "Accessories" chapter. See the operating instructions for the machine in question for a more detailed description of the individual machines and their functions.
5.7.6
MIG/MAG welding data display
To the left and right of the control displays are the "Parameter selection" buttons ( ). They are used to select welding parameters to be displayed.
Each press of the button advances the display to the next parameter (LEDs next to the button indicate the selection). After the last parameter is reached, the system starts again from the beginning.
Figure 5-10
The display shows:
• Nominal values (before welding)
• Actual values (during welding)
• Hold values (after welding)
Parameter
Welding current
Material thickness
Wire feed speed
Welding voltage
Welding performance
Nominal values
Actual values
Hold values
When settings are changed (e.g. wire feed speed) the display immediately switches to nominal value setting.
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5.7.7
Conventional MIG/MAG Welding (GMAW non synergic)
• With wire-feed speeds less than 8 m/min select JOB 188.
• With wire-feed speeds over 8 m/min select JOB 187.
You can only change the JOB number when no welding current is flowing.
Operating element
Action Result
Select JOB list.
1 x
(LED is on)
Set JOB number.
Wait 3 s until the setting has been applied.
Display
5.7.7.1
Setting the operating point (welding output)
The operating point (welding performance) is set using the wire-feed speed and the welding voltage.
Operating element
Action Result n x
Switch the display between:
Welding current (display of actual and hold value only)
Operating element
Material thickness
Wire speed
After welding, the values used last from the main program are displayed.
The settings are made using the rotary dials for welding parameter setting and arc length correction.
Action Result
Increase or reduce the welding performance via the wire speed parameter.
JOB 188: from 1-8 m/min
JOB 187: from 8-21 m/min
Operating element
Action Result
Set the welding voltage.
Setting range:
-9.9 V-9.9 V
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5.7.8
forceArc / forceArc puls
Heat-reduced, directionally stable and powerful arc with deep penetration for the upper power range.
Figure 5-11
• Smaller included angle due to deep penetration and directionally stable arc
• Excellent root and sidewall fusion
• Secure welding also with very long stick-outs
• Reduced undercuts
• Un-, low- and high-alloyed steels as well as high-tensile fine-grained building steels
• Manual and automated applications forceArc welding from:
Material
Steel
CrNi
Gas
Ar 91 –99%
Ar 80 –90%
Ar 91 –99%
0.8 1
Wire Ø (mm)
JOB JOB JOB
190 17.0 254 12.0 255
1.2
9.5
JOB
256
189 17.0 179 12.0 180
- - 251 12.0 252
9.5
12.0
181
253
1.6
7.0
6.0
6.0
You can make use of these properties after selecting the forceArc process (see the "Selecting a
MIG/MAG welding task" chapter).
As with pulse arc welding, it is important to make sure of a good welding current connection.
• Keep welding current cables as short as possible and ensure that cable cross-sections are adequate!
• Fully unroll welding current cables, torche hose packages and, if applicable, intermediate hose packages. Avoid loops!
• Use welding torches, preferably water-cooled, that are suitable for the higher power range.
• Use welding wire with adequate copper coating when welding steel. The wire spool should have layer spooling.
Unstable arc!
NOTE
Welding current cables that are not fully unrolled can cause faults in the arc (flickering).
• Fully unroll welding current cables, torch hose packages and, if applicable, intermediate hose packages. Avoid loops!
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5.7.9
rootArc/rootArc puls
Short arc with easy weld modelling capabilities for effortless gap bridging and positional welding.
Figure 5-12
• Reduced spatter compared to standard short arc
• Good root formation and secure sidewall fusion
• Un-alloyed and low-alloy steels
• Manual and automated applications rootArc welding up to:
Material
Steel
Gas
CO2
Ar 80 –90%
0.6
JOB
-
0.8
-
JOB
- -
JOB
-
Wire Ø (mm)
0.9 1
JOB
1.2
JOB
1.6
JOB
- 204 7.0 205 5.0 - -
- - - - - - 206 8.0 207 6.0 - -
NOTE
Unstable arc!
Welding current cables that are not fully unrolled can cause faults in the arc (flickering).
• Fully unroll welding current cables, torch hose packages and, if applicable, intermediate hose packages. Avoid loops!
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5.7.10
MIG/MAG program sequence ("Program steps" mode)
NOTE
Changes to the welding parameters can only be made when the key switch is in position "1".
5.7.10.1
Selecting the program sequence parameters using wire feed unit control M3.70
Operating
Element
Action Result Display
Select parameter in the program sequence n x
Setting welding parameters
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5.7.10.2
MIG/MAG overview of parameters, M3.70
46
6
7
8
3
4
5
Basic Parameters
Item Meaning / Explanation
1
2
9
10
11
12
13
14
Gas pre-flow time
P
START
Wire speed, relative
Arc length correction
Duration
Slope duration from P
START
to P
A
P
A
Wire speed, absolute
Dynamics
Duration (spot time and superpulse)
P
B
Wire speed, relative
Arc length correction, relative
Duration
Slope duration from P
A
to P
END
P
END
Wire speed, relative
Arc length correction
Duration (superpulse)
Gas post-flow time
Superpulses
Figure 5-13
Setting Range
0.0s to 20.0s
1% to 200%
-9.9V to +9.9V
0.0s to 20.0s
0.0s to 20.0s
0.1 m/min to 40 m/min
-40 to +40
0.01s to 20.0s
1% to 200%
-9.9V to +9.9V
0.01s to 20.0s
0.0s to 20s
1% to 200%
-9.9V to +9.9V
0.0s to 20s
0.0s to 20s
On / Off
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5.7.11
Main program A mode
Operating element
Action Result n x
Change welding data display over to program display.
(LED PROG is on)
Select program number.
Display example: Program "1".
Display n x
Select program sequence parameter
"Main program (P
A
)".
(LED is on)
Set wire speed.
(Absolute value)
Set arc length correction.
Display example: "-0.8 V" correction
(Setting range: -9.9 V to +9.9 V)
Select "Dynamic" program sequence parameter.
(LED is on) 1 x
Set dynamic. (Setting range 40 to -40)
40: Arc hard and narrow.
-40: Arc soft and wide.
NOTE
Changes to the welding parameters can only be made when the key switch is in position "1".
5.7.12
MIG/MAG automatic cut-out
NOTE
The welding machine ends the ignition process or the welding process with an
• ignition fault (no welding current flows within 5 s after the start signal)
• arc interruption (arc is intrerupted for longer than 5 s)
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5.7.13
Standard MIG/MAG torch
The MIG welding torch trigger is essentially used to start and stop the welding process.
Operating elements
Torch trigger
Functions
• Start/stop welding
Other functions are also possible by tapping the torch trigger, depending on the machine type and control configuration:
• Change over between welding programs (see "Program changeover with standard torches (P8)" chapter).
• Change over between pulse and standard welding in the special latched operating mode.
• Switching between wire feed units in dual operation mode (see chapter "M3.70/M3.71 machine controls – special parameters, single or double operation setting (P10)")
5.7.14
MIG/MAG special-torches
Function specifications and more indepth information can be found in the operating manual for the relevant welding torch!
5.7.14.1
Program- and Up- / down operation
Figure 5-14
Item Symbol Description 0
1 Welding torch function changeover switch (special welding torch required)
Changing over programs or JOBs
Infinite adjustment of welding performance.
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5.7.14.2
MIG/MAG Push/Pull welding torch
The most important requirement for the greatest degree of efficiency and weld seam quality is the smooth conveyance of the wire electrode. This is particularly problematic when:
• Longer tube packages are used,
• Wire electrodes have poor sliding properties,
• Wire electrodes have poor bending strength and
• An especially even wire outlet speed is required.
In this process, additional conveying aids in the torch produce significant improvements in comparison with pure feed wire conveyors. In addition to a pushing wire feed (PUSH) in the power source / wire feed case, a pulling wire feed (PULL) is used in the torch.
The two feed motors are synchronised by a current regulator.
Welding torches without potentiometers
Operating elements Functions
1 torch trigger Welding On/Off
Push/Pull torch with one potentiometer
NOTE
Changeover switch in WF unit to "Up / Down" (see "Internal operating elements" chapter)
Infinitely adjustable setting of welding performance (Up/Down function)
Operating elements
1 torch trigger
1 rotary dial
5.7.14.3
Pin assignment
Functions
Welding On/Off
Infinite adjustment of the wire speed
No potentiometers With potentiometer for wire feeding speed
Figure 5-15
With potentiometers for wire feeding speed and arc length correction
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5.7.14.4
Switching between Push/Pull and intermediate drive
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
CAUTION
Test!
Before re-commissioning, it is essential that an "inspection and test during operation" is carried out conforming to IEC / DIN EN 60974-4 "Arc welding devices - inspection and testing during operation"!
• For detailed instructions, please see the standard operating instructions for the welding machine.
The plugs are located directly on the M3.7x printed circuit board.
Plug Function on X24 on X23
Operation with Push/Pull welding torch (factory setting)
Operation with intermediate drive
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Design and function
MIG/MAG welding
5.7.15
Expert menu (MIG/MAG)
The expert menu includes functions and parameters which are either not set on the machine control, or which do not require regular setting.
5.7.15.1
Selection
NOTE
ENTER (Enter the menu)
• Keep the "welding parameters" push-button pressed for 3 s.
NAVIGATION (Navigate the menu)
• Select parameters by pressing the "welding parameters" push-button.
• Set or change the parameters by turning the "welding parameter setting" rotary knob.
EXIT (Exit the menu)
• After 3 s, the machine will return automatically to the ready-to-operate status.
ENTER NAVIGATION EXIT
3 s
3 s m /m in
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Figure 5-16
51
Design and function
MIG/MAG welding
Display Setting/selection
Correct wire burn-back (setting range 0 –499)
If too high a value is set, a large ball will form at the tip of the wire electrode (bad reignition) or the wire electrode sticks to the contact tip. If too low a value is set, the wire electrode sticks to the weld pool.
• Increase value > increase wire burn-back
• Decrease value > decrease wire burn-back
Setting JOB-dependent program limit/n-cycle
The JOB-dependent program limit allows you to limit the number of programs that can be selected in the selected JOB to (2...9). This option can be set individually per JOB. In addition, a legacy option to set a "global program limit" is also available. To set this option use special parameter P4. This setting is then applied to all JOBs for which no
JOB-dependent program limit has been set (see the special parameters description).
You can also use the "Special latched (n-cycle)" operating mode if special parameter 8 is set to 2. In this case (JOB-dependent program switching activated, special parameter
8 = 2, special latched) you can switch to the next program by tapping the torch trigger in the main program (see the special parameters description).
1
2 –9
No JOB-dependent program limit
JOB-dependent program limit for max. selectable programs.
Change welding process (process switching)
With this function activated the welding process switches from standard arc welding to pulse arc welding. Switching is effected by either tapping the torch trigger (special latched) or by activating the superPuls function (switch between program P
A
and P
B
). on Function activated. off Function deactivated.
Pulse arc welding process (program P
START
)
The pulse arc welding process can be activated in the start program (P
START
) with the special non-latched and special latched operating modes. on off
Function activated.
Function deactivated.
Pulse arc welding process (program P
END
)
The pulse arc welding process can be activated in the end program (P
END
) with the special non-latched and special latched operating modes. on Function activated. off Function deactivated.
Ignition type (MIG/MAG)
Application: Low-spatter ignition, e.g. for aluminium and chrome/nickel materials.
0 = Traditional arc ignition
1 =
2 =
Arc ignition with wire return for push/pull applications
Arc ignition with wire return for non-push/pull applications
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Design and function
TIG welding
5.8
TIG welding
5.8.1
Welding torch connection
NOTE
TIG welding torches to be connected to a Euro torch connector are available in two versions:
• TIG combi welding torches are connected to the Euro torch connector of the wire feeder and to the (-) welding current plug of the power source.
• TIG welding torches of the EZA version are connected to the Euro torch connector of the wire feeder only. To do so, the welding current lead of the intermediate hose package must be connected to the (-) welding current connection at the rear of the unit!
Figure 5-17
Item Symbol Description 0
1 Welding torch
2
3
4
5
6
7
Welding torch hose package
Welding torch connection (Euro or Dinse torch connector)
Welding current, shielding gas and torch trigger integrated
Quick connect coupling (blue) coolant supply
Quick connect coupling (red) coolant return
"-" welding current connection socket
• TIG welding: Welding current connection for welding torch
Power source
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Design and function
TIG welding
• Insert the central plug for the welding torch into the central connector and screw together with crown nut.
• Insert the welding current plug of the combi welding torch into the (-) welding current connection socket and lock into place by turning to the right (only in case of a separate welding current connection).
• Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings:
Return line red to quick connect coupling, red (coolant return) and supply line blue to quick connect coupling, blue (coolant supply).
5.8.2
Welding task selection
NOTE
Selection of a welding task involves the interaction of the controls on the welding machine and the wire feed unit. After the basic settings are made on the welding machine, the operating point and other parameters can be set on the wire feed unit.
Operating element m /m in
Figure 5-18
Action Result Display n x
The various welding processes are run through until the signal light for the required welding process comes on.
Welding current is set
The nominal values for the welding current and welding voltage are displayed.
Setpoint setting
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Design and function
TIG welding
5.8.3
TIG arc ignition
5.8.3.1
Liftarc ignition
Figure 5-19
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). b) Incline the torch over the torch gas nozzle to produce a gap of approx. 2-3 mm between the electrode tip and the workpiece. The arc ignites and the welding current is increased, depending on the operating mode set, to the ignition or main current set. c) Lift off the torch and swivel to the normal position.
Ending the welding process: Release or press the torch trigger depending on the operating mode selected.
5.8.4
TIG automatic cut-out
NOTE
The welding machine ends the ignition process or the welding process with an
• ignition fault (no welding current flows within 5 s after the start signal)
• arc interruption (arc is intrerupted for longer than 5 s)
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Design and function
TIG welding
5.8.5
TIG arc ignition
5.8.5.1
Liftarc ignition
Figure 5-20
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). b) Incline the torch over the torch gas nozzle to produce a gap of approx. 2-3 mm between the electrode tip and the workpiece. The arc ignites and the welding current is increased, depending on the operating mode set, to the ignition or main current set. c) Lift off the torch and swivel to the normal position.
Ending the welding process: Release or press the torch trigger depending on the operating mode selected.
5.8.6
Pulses, function sequences
5.8.6.1
Explanation of signs and functions
Symbol Meaning
Press torch trigger
Release torch trigger
Tap torch trigger (press briefly and release)
Shielding gas flowing
I Welding output
Gas pre-flows
Gas post-flows
Non-latched
Special, non-latched
Latched
Special, latched t Time
P
START
Ignition program
P
A
Main program
P
B
Reduced main program
P
END
End program tS1 Slope duration from PSTART to PA
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Non-latched mode
Figure 5-21
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
• Release torch trigger.
• Arc is extinguished.
• Gas post-flow time elapses.
Special, non-latched
Design and function
TIG welding
Figure 5-22
Selection
• Select non-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 with pre-selected setting in start program “P
START
”.
• After the “tstart” ignition current time elapses, the welding current rises with the set upslope time “tS1” to the main program “P
A
”.
Step 2
• Release torch trigger.
• The welding current reduces with the downslope time “tSe” to the end program “P
END
”.
• After the end current time “end” elapses, the arc will extinguish.
• Gas post-flow time elapses.
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Design and function
TIG welding
Latched mode
Figure 5-23
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
• Release torch trigger (no effect)
Step 3
• Press torch trigger (no effect)
Step 4
• Release torch trigger
• Arc is extinguished.
• Gas post-flow time elapses.
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TIG welding
Latched special
Figure 5-24
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
START
".
Step 2
• Release torch trigger.
• Slope on main program "P
A
".
The slope on main program P
A
is given at the earliest after the set time t
START elapses and at the latest when the torch trigger is released.
Tapping can be used to switch to the reduced main program "P
B
". Repeated tapping will switch back to the main program "P
A
".
Step 3
• Press the torch trigger.
• Slope to end program "P
END
".
Step 4
• Release torch trigger.
• Arc is extinguished.
• Gas post-flow time elapses.
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Design and function
MMA welding
5.9
MMA welding
5.9.1
Welding task selection
NOTE
Selection of a welding task involves the interaction of the controls on the welding machine and the wire feed unit. After the basic settings are made on the welding machine, the operating point and other parameters can be set on the wire feed unit.
Operating element m /m in
Figure 5-25
Action Result Display n x
The various welding processes are run through until the signal light for the required welding process comes on.
Welding current is set
The nominal values for the welding current and welding voltage are displayed.
Setpoint setting
5.9.1.1
Setting using the stick electrode diameter
The welding current can also be set using the stick electrode diameter:
The welder sets the stick electrode diameter being used and the control calculates the relevant welding current for the electrode.
Control element Action Result
Switch to
Display
Current stick electrode diameter is displayed
1 x stick electrode diameter
Stick electrode diameter being used is set Stick electrode diameter is displayed
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MMA welding
5.9.1.2
Arcforce
NOTE
The settings are made on the wire feed unit control.
Operating element
Action Result Display
Select arcforce welding parameter
LED for the button is on.
Arcforcing setting for electrode types:
(Setting range -40 to 40)
Negative values
Values around zero
Positive values
Rutile
Basic
Cellulose
5.9.1.3
Hotstart
The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = Hotstart time b) = Hotstart current
I = t =
Welding current
Time
Figure 5-26
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Design and function
Remote control
5.10
Remote control
NOTE
The remote controls are operated via the 19-pole remote control connection socket
(analogue) or the 7-pole remote control connection socket (digital), depending on the model.
Please note the relevant documentation of the accessory components.
5.11
Interfaces for automation
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
CAUTION
Damage due to incorrect connection!
Accessory components and the power source itself can be damaged by incorrect connection!
• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.
• Comprehensive descriptions can be found in the operating instructions for the relevant accessory components.
• Accessory components are detected automatically after the power source is switched on.
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5.11.1
Remote control connection socket, 19-pole
Design and function
Interfaces for automation
Pin
A
C
D
E
F/S
G
P
R
U/V
Figure 5-27
Signal form Short description
Output Connection for PE cable screen
Output
Input
Output
Reference voltage for potentiometer 10 V (max. 10 mA)
Control voltage specification (0 V –10 V) – wire feed speed
Reference potential (0 V)
Input
Input
Input
Input
Output
Welding power start/stop (S1)
Control voltage specification (0 V –10 V) – arc length correction
Activation of control voltage specification for wire feed speed (S2)
For activation, put signal to reference potential 0 V (pin E)
Activation of control voltage specification for arc length correction (S3)
For activation, put signal to reference potential 0 V (pin E)
Supply voltage push/pull welding torch
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Design and function
Special parameters (advanced settings)
5.12
Special parameters (advanced settings)
Special parameters ( P1 to Pn ) are applied for customer-specific configuration of machine functions. This allows the user maximum flexibility in optimising their requirements.
These settings are not configured directly on the machine control since a regular setting of the parameters is generally not required. The number of selectable special parameters can deviate between the machine controls used in the welding system (also see the relevant standard operating instructions).
If required, the special parameters can be reset to the factory settings.
NOTE
ENTER (Enter the menu)
• Switch off machine at the main switch.
• Press and hold the "left parameter selection" button and switch the machine on again at the same time.
NAVIGATION (Navigate the menu)
• Select parameters by turning the "welding parameter setting" rotary dial.
• Set or change the parameters by turning the "arc length correction/select welding program" rotary dial.
EXIT (Exit the menu)
• Press the "right parameter selection" button (switch machine off and on again).
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Special parameters (advanced settings)
5.12.1
Selecting, changing and saving parameters
ENTER
0 l
A M P +
HOLD
NAVIGATION
EXIT
VOLT
PROG kW m /m in m /m in
Display
Figure 5-28
Setting/selection
Ramp time for wire inching
0 = normal inching (10s ramp time)
1 = fast inching (3s ramp time) (Ex works)
Block program "0"
0 = P0 enabled (Ex works)
1 = P0 blocked
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Special parameters (advanced settings)
Display Setting/selection
Display mode for Up/Down welding torch with one-digit 7-segment display (two keys)
0 = normal display (ex works)
program number/JOB or welding performance/welding voltage correction is shown
1 = alternating display
display switches between program number and welding method
Program limitation
Programs 1 to max. 15
Ex works: 15
Special cycle in the special latched and non-latched operating modes
0 = normal (previous) non-latched/latched (Ex works)
1 = WF3 cycle for non-latched/latched
Correction operation, threshold value setting
0 = correction operation switched off (Ex works)
1 = correction operation on
"Main program (PA)" flashing
Program changeover with standard torch
0 = no program changeover (Ex works)
1 = special latched
2 = specific latched special (n cycle active)
Lat. and sp. lat. tapping start
0 = no latched tapping start (Ex works)
1 = latched tapping start possible
One or two-wire feed operation
0 = single operation (Ex works)
1 = dual operation, this unit is the "master"
2 = dual operation, this unit is the "slave"
Special latched tapping time
0 = tapping function switched off
1 = 300ms (Ex works)
2 = 600ms
JOB list changeover
0 = task-oriented JOB list
1 = actual JOB list (Ex works)
2 = actual JOB list, JOB changeover activated via accessories
Lower limit remote JOB changeover
Lowest JOB that can be selected using PowerControl 2 torches.
Lower limit: 129 (Ex works)
Upper limit remote JOB changeover
JOB range of the POWERCONTROL2 torch
Upper limit: 169 (Ex works)
HOLD function
0 = HOLD values are not displayed
1 = HOLD values are displayed (Ex works)
Block JOB mode
0 = Block JOB mode not enabled (Ex works)
1 = Block JOB mode enabled
Program selection with standard torch trigger
0 = no program selection (Ex works)
1 = program selection possible
Mean value display for super pulses
0 = Function switched off
1 = Function switched on (factory setting)
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Special parameters (advanced settings)
Display Setting/selection
Predefined execution of the pulsed arc welding process in the PA program
1 = If the superPuls and welding process switching functions are available and activated, the pulsed arc welding process is always executed in the main program PA (ex factory).
0 = Predefined execution of the pulsed arc welding process in the PA program is disabled.
Predefined absolute value for relative programs
Start program (P
START
), down-slope program (P
B
) and end program (P
END
) can be set relative to the main program (P
A
) or in an absolute manner, as desired.
0 =
1 =
Relative parameter setting (ex factory)
Absolute parameter setting
5.12.2
Reset to factory settings
NOTE
All special parameters saved by the user will be overwritten by the factory settings!
Operating element
Action Result
Switch off welding machine
Keep the button pressed
Switch on welding machine
Release the button, wait about 3 seconds
Switch off welding machine and restart in order to put the changes into effect
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Design and function
Special parameters (advanced settings)
5.12.3
The special parameters in detail
Ramp time for wire inching (P1)
The wire inching starts with a speed 1.0 m/min for 2 secs. It is subsequently increased to a ramp function to 6.0 m/min. The ramp time can be set between two ranges.
During wire inching, the speed can be changed by means of the welding parameter setting rotary dial.
Changing the speed has no effect on the ramp time.
Program "0", releasing the program block (P2)
The program P0 (manual setting) is blocked. Only operation with P1-P15 is possible, irrespective of the key switch position.
Display mode for Up/Down welding torch with one-digit 7-segment display (P3)
Normal display:
Program operation: Program number
Up/down operation: Up/down setting
Alternating display:
Program operation: Change program number and welding process (pulse/non-pulse)
Up/down operation: Change up/down setting and up/down symbol
Program limit (P4)
Program selection can be limited with the special parameter P4.
• The setting is adopted for all JOBs.
• Program selection depends on the position of the "welding torch function" changeover switch (see
"Machine description"). Programs can only be switched when the changeover switch is in the
"program" position.
• Programs can be switched by means of a connected remote control or special welding torch.
• If a special welding torch or a remote control is not connected, it is only possible to switch programs by means of the "arc length correction/select welding program" rotary dial (see "Machine description").
Special cycle in the operating modes special latched and non-latched (P5)
With the special sequence activated, the start of the welding process changes as follows:
Sequence for special non-latched mode/special latched mode:
• Start program "P
START
"
• Main program "P
A
"
Sequence for special non-latched mode/special latched mode with custom sequence activated:
• Start program "P
START
"
• Reduced main program "P
B
"
• Main program "P
A
"
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Special parameters (advanced settings)
Correction operation, threshold value setting (P7)
The correction operation is switched on and off for all JOBs and their programs at the same time. A correction operation is specified for wire speed (DV) and welding voltage correction (Ukorr) for each JOB.
The correction value is saved separately for each program. The correction range can be maximum 30% of the wire speed and +/-9.9 V welding voltage.
Figure 5-29
Example for the operating point in correction mode:
The wire speed in one program (1 to 15) is set on 10.0 m/min.
This corresponds to a welding voltage (U) of 21,9 V. When the key switch is set to "0" position, welding in this program can only be carried out with these values.
To allow the welder also to perform wire and voltage correction in program mode, the correction mode must be switched on and limit values for wire and voltage must be specified.
Setting of the correction limit value = WFlimit = 20% / Ulimit = 1.9 V
Now the wire speed can be corrected by 20% (8.0 up to 12.0 m/min) and the welding voltage by +/-1.9 V
(3.8 V).
In the example the wire speed is set on 11.0 m/min. This corresponds to a welding voltage of 22 V
Now the welding voltage can be corrected by further 1.9 V (20.1 V and 23.9 V).
The values for voltage and wire-speed correction will be reset if the key switch is moved to the "1" setting.
Setting the correction range:
• Switch on the "Correction operation" special parameter (P7=1) and save the setting.
(See chapter entitled "Selecting, changing and saving parameters".)
• Key switch to position "1".
• Set correction range according to the following table:
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Special parameters (advanced settings)
Operating element
Action Result x n
Press button until "PROG" LED comes on.
Left: Wire feed speed
Right: Program number
4 s
Press button and hold down for approx.
4 s
Left: Current limit value of the wire feed speed correction
Right: Current limit value of the voltage correction
Set limit value for the wire feed speed correction
Set limit value for voltage correction
After approx. 5 s without further user intervention, the set values are adopted and the display switches back to the program display,
• Key switch back to position "0"!
Display (examples)
Left Ri g ht
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Design and function
Special parameters (advanced settings)
Switching programs with the standard torch trigger (P8)
Special latched (latched absolute program sequence)
• Cycle 1: absolute program 1 is run
• Cycle 2: absolute program 2 is run after completion of "tstart".
• Cycle 3: absolute program 3 is run until the "t3" time has elapsed. The program then switches automatically to absolute program 4.
Accessory components such as remote controls or special torches may not be connected!
Program switching at the wire feed unit control is disabled.
Figure 5-30
Specific latched special (n cycle)
In the n cycle program sequence, the unit starts in the 1st cycle with start program P start
from P
1
In the second cycle, the machine switches to absolute program 2, once the start time "tstart" has elapsed.
Tapping switches to other programs (P
A1
to max. P
A9
).
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Figure 5-31
71
Design and function
Special parameters (advanced settings)
The number of programs (P
An
) corresponds to the cycle number specified under N cycle.
1st cycle
• Press and hold torch trigger.
• Shielding gas is expelled (gas pre-flows).
• Wire feed motor runs at "creep speed".
• Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P
START from P
A1
)
2nd cycle
• Release torch trigger.
• Slope to main program P
A1
.
The slope to main program P
A1
is given at the earliest after the set time t
START elapses and at the latest when the torch trigger is released. Tapping (pressing briefly and releasing within 0.3 sec) can switch to other programs. Programs P
A1
to P
A9 are possible.
3rd cycle
• Press and hold torch trigger.
• Slope to end program P
END
from P
AN
. The program can be stopped at any time by pressing the torch trigger longer than 0.3 sec. P
END
from P
AN
is then executed.
4th cycle
• Release torch trigger.
• WF motor stops.
• Arc is extinguished after the pre-selected wire burn-back time elapses.
• Gas post-flow time elapses.
Latched/special-latched tap start (P9)
In latched – tap start – operating mode it is possible to switch straight to the second step by tapping the torch trigger; it is not necessary for current to be flowing.
The welding can be halted by pressing the torch trigger for a second time.
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Design and function
Special parameters (advanced settings)
"Single or dual operation" (P10) setting
NOTE
If the system is fitted with two wire feeds, no further accessory components may be operated on the 7-pole connection socket (digital)!
This relates to digital remote controls, robot interfaces, documentation interfaces, welding torches with digital control lead connection, etc.
No second wire feed may be connected in single operation (P10 = 0)!
• Remove connections to the second wire feed
In dual operation (P10 = 1 or 2), both wire feed units must be connected and configured differently on the controls for this operating mode!
• Configure one wire feed unit as the master (P10 = 1)
• Configure the other wire feed unit as a slave (P10 = 2)
Wire feed units with key switches (optional, see Protecting welding parameters from unauthorised access chapter) must be configured as masters (P10 = 1).
The wire feed configured as the master is active after the welding machine is switched on. There are no other functional differences between the wire feeds.
Latched special tapping time setting (P11)
The tapping time for changing over between the main program and reduced main program can be set in three levels.
0 = no tapping
1 = 320ms (factory setting)
2 = 640ms
JOB list switching (P12)
Value Designation
0
1
Task-oriented
JOB list
Actual JOB list
Explanation
The JOB numbers are sorted by welding wires and shielding gases.
JOB numbers may be skipped during selection where relevant.
JOB numbers correspond to the actual memory cells. Each JOB can be selected; no memory cells are skipped during selection.
2 Actual JOB list,
JOB changeover active
As for the actual JOB list. JOB changeover is also possible with accessory components, such as the PowerControl 2 torch.
Lower and upper limits of the remote JOB changeover process (P13, P14)
The highest and lowest JOB numbers which can be selected using accessory components, such as the
PowerControl 2 torch.
Avoids an accidental changeover into undesirable or undefined JOBs.
Hold function (P15)
Hold function active (P15 = 1)
• Mean values for the last main program parameters used for welding are displayed.
Hold function not active (P15 = 0)
• Setpoint values for the main program parameters are displayed.
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Special parameters (advanced settings)
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, a total of 27 JOBs (welding tasks) divided into three blocks can be called up using accessory components.
The following settings must be made in order to be able to use block JOB mode:
• Switch the "Program or Up/Down function" changeover switch to "Program"
(see "Internal operating elements" chapter).
• Set the JOB list to actual JOB list (special parameter P12 = "1")
• Enable block JOB mode (special parameter P16 = "1")
• Change to block JOB mode by selecting one of the special JOBs 129, 130 or 131.
(See the "Selecting MIG/MAG welding tasks" chapter.)
Simultaneous operation with interfaces such as RINT X12, BUSINT X11, DVINT X11 or digital accessory components such as is the R40 remote control is not possible!
Allocation of JOB numbers to the display on the accessory components
JOB no. Display/selection on the accessory component
Special JOB 1
Special JOB 2
0
129
1
141
2
142
3
143
4
144
5
145
6
146
7
147
8
148
9
149
130 151 152 153 154 155 156 157 158 159
Special JOB 3
JOB 0:
131 161 162 163 164 165 166 167 168 169
This JOB allows you to set the welding parameters manually.
Selection of JOB 0 can be prevented via the key switch or with the "block program 0" parameter (P2).
(See "List of special parameters" chapter)
Key switch position 0, or special parameter P2 = 0: JOB 0 is blocked.
Key switch position 1, or special parameter P2 = 1: JOB 0 can be selected.
JOBs 1-9:
Nine JOBs can be called up in each special JOB (see table).
Nominal values for wire speed, arc correction, dynamics etc must be defined in advance in these JOBs.
This can be done easily with the PC300.NETsoftware.
If the software is not available, user-defined JOB lists can be created in the special JOB areas with the
"Copy to" function. (See explanations about this in the "Switching JOB lists (P12)" chapter)
Selecting programs with the standard torch trigger (P17)
Allows you to select a program or switch a program before starting welding.
You switch to the next program by tapping the torch trigger. Once the last enabled program is reached, you start again at the beginning.
• Program 0 is the first enabled program, provided that it is not blocked.
(see also special parameter P2).
• The last enabled program is P15.
-
If the programs are not limited by special parameter P4 (see special parameter P4).
-
Or if the programs are limited for the selected JOB by the n cycle setting (see parameter P8).
• Welding starts when the torch trigger is held for longer than 0.64 s.
You can select programs with the standard torch trigger in all operating modes (non-latched, special nonlatched. latched and special latched).
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Design and function
Machine configuration menu
Mean value display for super pulses (P19)
Function active (P19 = 1)
• For super pulses, the mean power from program A (P
A
) and program B (P
B
) is shown in the display
(factory setting).
Function inactive (P19 = 0)
• Only power from program A is displayed for super pulses.
NOTE
If the function is enabled and only "000" is shown on the machine display, this is a rare case of an incompatible system set-up. Solution: Disable special parameter P19.
Predefined execution of the pulsed arc welding process in the PA program (P20)
Pulse arc welding machines only.
NOTE
Function active (P20 = 1)
• If the superPuls and welding process switching functions are available and activated, the pulsed arc welding process is always executed in the main program PA (ex factory).
Function inactive (P20 = 0)
• Predefined execution of the pulsed arc welding process in the PA program is disabled.
Predefined absolute value for relative programs (P21)
Start program (P
START
), down-slope program (P
B
) and end program (P
END
) can be set relative to the main program (P
A
) or in an absolute manner, as desired.
Function active (P21 = 1)
• Absolute parameter setting
Function inactive (P21 = 0)
• Relative parameter setting (ex factory)
5.13
Machine configuration menu
5.13.1
Selecting, changing and saving parameters
NOTE
ENTER (Enter the menu)
• Switch off the machine at the main switch.
• Press and hold the "welding parameters" push-button and switch the machine on again at the same time.
NAVIGATION (Navigate the menu)
• Select parameters by turning the "welding parameter setting" rotary knob.
• Set or change parameters by turning the "arc length correction/select welding program" rotary knob.
EXIT (Exit the menu)
• Press the "parameter selection right" push-button (switch machine off and on again).
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Design and function
Machine configuration menu
ENTER
0 l
+
EXIT
VOLT
PROG kW
0 l
NAVIGATION
m /m in
Display
Figure 5-32
Setting/selection
Lead resistance 1
Lead resistance for the first welding circuit 0 mΩ–60 mΩ (8 mΩ ex works).
Lead resistance 2
Lead resistance for the second 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
• 5 min.–60 min. = Time to activation of power-saving mode in case of inactivity.
• off = inactivated
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Design and function
Machine configuration menu
5.13.2
Matching the cable resistance
The resistance value of cables can either be set directly or it can be matched using the power source.
The factory setting of the power sources is 8 m-ohm. This value correponds to a 5 m earth cable, a 1.5 m intermediate hose package and a 3 m water-cooled welding torch. With other hose package lengths, it is necessary to carry out a +/- voltage correction to optimise welding properties. The voltage correction value can be set close to zero by means of re-matching the cable resistance. It is recommended to match the electric cable resistance after replacing accessories such as torches or intermediate hose packages.
In case a second wire feeder is used the (rL2) parameter has to be adjusted. For all other configurations it is sufficient to match the (rL1) parameter.
1
0 l
50mm
2
+ m /m in
3
B
A
4
0 l
Figure 5-33
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Design and function
Machine configuration menu
1 Preparation
• Switch off the welding machine.
• Remove the gas nozzle from the welding torch.
• Cut the wire flush on the contact tip.
• Slightly withdraw the wire at the wire feeder (approx. 50 mm). There should be no wire left in the contact tip.
2 Configuration
• Push the „Welding parameter“ button and simultaneously switch on the welding machine. Release the
“Welding parameter” button.
• The corresponding parameter can now be selected using the „Welding parameter setting“ rotary knob.
It is essential to match the rL1 parameter for all machine combinations. A second matching with the rL2 parameter has to be carried out if a second circuit is used on a welding system (e.g. two wire feeders on one power source).
3 Matching / Measuring
• Carefully touch the torch with the contact tip on a cleaned area of the workpiece and push the torch trigger for approx. 2 s. A short-circuit current temporarily flows which is used to determine and display the new cable resistance. The value can be between 0 m Ω and 40 mΩ. The newly established value is instantly saved and does not have to be confirmed. If no value is shown on the right display the measurement failed. Measuring has to be carried out again.
4 Restoring the machine
• Switch off the welding machine.
• Screw the gas nozzle onto the welding torch again.
• Switch on the welding machine.
• Re-inch the welding wire.
5.13.3
Power-saving mode
The power-saving function can be activated either by pressing the button for a longer time (see chapter
"Machine description – Short overview") or by setting a parameter in the configuration menu (time-based power-saving mode).
When power-saving mode is activated, both machine displays show the horizontal digit in the centre of the display only.
Pressing any operating element (e.g. tapping the torch trigger) deactivates power-saving mode and the machine is ready for welding again.
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Maintenance, care and disposal
General
6 Maintenance, care and disposal
DANGER
Risk of injury from electric shock!
Cleaning machines that are not disconnected from the mains can lead to serious injuries!
• Disconnect the machine completely from the mains.
• Remove the mains plug!
• Wait for 4 minutes until the capacitors have discharged!
6.1
General
When used in the specified environmental conditions and under normal operating conditions, this machine is largely maintenance-free and requires a minimum of care.
There are some points, which should be observed, to guarantee fault-free operation of your welding machine. Among these are regular cleaning and checking as described below, depending on the pollution level of the environment and the length of time the unit is in use.
6.2
Maintenance work, intervals
CAUTION
Electric current!
Repairs may only be carried out by authorised specialist staff!
• Do not remove the torch from the hose package!
• Never clamp the torch body in a vice or similar, as this can cause the torch to be irreparably destroyed!
• If damage occurs to the torch or to the hose package which cannot be corrected as part of the maintenance work, the entire torch must be returned to the manufacturer
6.2.1
Daily maintenance tasks
• Check that all connections and wearing parts are hand-tight and tighten if necessary.
• Check that all screw and plug connections and replaceable parts are secured correctly, tighten if necessary.
• Remove any spatter.
• Clean the wire feed rollers on a regular basis (depending on the degree of soiling).
6.2.1.1
Visual inspection
• Check hose package and power connections for exterior damage and replace or have repaired by specialist staff as necessary!
• Mains supply lead and its strain relief
• Gas tubes and their switching equipment (solenoid valve)
• Other, general condition
6.2.1.2
Functional test
• Check correct mounting of the wire spool.
• Welding current cables (check that they are fitted correctly and secured)
• Gas cylinder securing elements
• Operating, message, safety and adjustment devices (Functional test)
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Maintenance, care and disposal
Maintenance work
6.2.2
Monthly maintenance tasks
6.2.2.1
Visual inspection
• Casing damage (front, rear and side walls)
• Wheels and their securing elements
• Transport elements (strap, lifting lugs, handle)
• Check coolant tubes and their connections for impurities
6.2.2.2
Functional test
• Selector switches, command devices, emergency stop devices, voltage reducing devices, message and control lamps
• Check that the wire guide elements (inlet nipple, wire guide tube) are fitted securely.
6.2.3
Annual test (inspection and testing during operation)
NOTE
The welding machine may only be tested by competent, capable personsl.
A capable person is one who, because of his training, knowledge and experience, is able to recognise the dangers that can occur while testing welding power sources as well as possible subsequent damage and who is able to implement the required safety procedures.
For further information, please see the accompanying supplementary sheets "Machine and Company Data, Maintenance and Testing, Warranty"!
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed.
6.3
Maintenance work
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Repair and maintenance work may only be performed by qualified authorised personnel; otherwise the right to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine. Return deliveries of defective equipment subject to warranty may only be made through your dealer. When replacing parts, use only original spare parts. When ordering spare parts, please quote the machine type, serial number and item number of the machine, as well as the type designation and item number of the spare part.
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Maintenance, care and disposal
Disposing of equipment
6.4
Disposing of equipment
NOTE
Proper disposal!
The machine contains valuable raw materials, which should be recycled, and electronic components, which must be disposed of.
• Do not dispose of in household waste!
• Observe the local regulations regarding disposal!
6.4.1
Manufacturer's declaration to the end user
• According to European provisions (guideline 2002/96/EG of the European Parliament and the Council of January, 27th 2003), used electric and electronic equipment may no longer be placed in unsorted municipal waste. It must be collected separately. The symbol depicting a waste container on wheels indicates that the equipment must be collected separately.
This machine is to be placed for disposal or recycling in the waste separation systems provided for this purpose.
• According to German law (law governing the distribution, taking back and environmentally correct disposal of electric and electronic equipment (ElektroG) from 16.03.2005), used machines are to be placed in a collection system separate from unsorted municipal waste. The public waste management utilities (communities) have created collection points at which used equipment from private households can be disposed of free of charge.
• Information about giving back used equipment or about collections can be obtained from the respective municipal administration office.
• EWM participates in an approved waste disposal and recycling system and is registered in the Used
Electrical Equipment Register (EAR) under number WEEE DE 57686922.
• In addition to this, returns are also possible throughout Europe via EWM sales partners.
6.5
Meeting the requirements of RoHS
We, EWM AG Mündersbach, hereby confirm that all products supplied by us which are affected by the
RoHS Directive, meet the requirements of the RoHS (Directive 2002/95/EC).
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Rectifying faults
Checklist for rectifying faults
7 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.
7.1
Checklist for rectifying faults
NOTE
The correct machine equipment for the material and process gas in use is a fundamental requirement for perfect operation!
Legend Symbol
Description
Fault/Cause
Remedy
Coolant error/no coolant flowing
Insufficient coolant flow
Check coolant level and refill if necessary
Air in the coolant circuit
see chapter "Vent coolant circuit"
Wire feed problems
Contact tip blocked
Clean, spray with anti-spatter spray and replace if necessary
Setting the spool brake (see "Setting the spool brake" chapter)
Check settings and correct if necessary
Setting pressure units (see "Inching wire electrodes" chapter)
Check settings and correct if necessary
Worn wire rolls
Check and replace if necessary
Wire feed motor without supply voltage (automatic cutout triggered by overloading)
Reset triggered fuse (rear of the power source) by pressing the key button
Kinked hose packages
Extend and lay out the torch hose package
Wire guide core or spiral is dirty or worn
Clean core or spiral; replace kinked or worn cores
Functional errors
Machine control without displaying the signal lights after switching on
Phase failure > check mains connection (fuses)
No welding performance
Phase failure > check mains connection (fuses)
Various parameters cannot be set
Entry level is blocked, disable access lock (see chapter entitled "Lock welding parameters against unauthorised access")
Connection problems
Make control lead connections and check that they are fitted correctly.
Loose welding current connections
Tighten power connections on the torch and/or on the workpiece
Tighten contact tip correctly
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Rectifying faults
Error messages (power source)
7.2
Error messages (power source)
NOTE
A welding machine error is indicated by an error code being displayed (see table) on the display on the machine control.
In the event of a machine error, the power unit is shut down.
The display of possible error numbers depends on the machine version
(interfaces/functions).
• Document machine errors and inform service staff as necessary.
• If multiple errors occur, these are displayed in succession.
Error Category a) b) c)
Possible cause Remedy
Error 1
(Ov.Vol)
Error 2
(Un.Vol)
- - x Mains overvoltage
- - x Mains undervoltage
Check the mains voltages and compare with the connection voltages of the welding machine
Error 3
(Temp)
Error 4
(Water) x - - Welding machine excess temperature xx x - Low coolant level
Error 5
(Wi.Spe)
Error 6
(gas)
Error 7
(Se.Vol)
Error 8
(no PE) x x
-
-
-
-
-
- x
Wire feeder, speedometer error
Shielding gas error
Secondary excess voltage
Allow the machine to cool down (mains switch to "1")
Top off the coolant
Leak in the coolant circuit > rectify the leak and top off the coolant
Coolant pump is not working > check excess current trigger on air cooling unit
Check the wire feeder speedometer is not issuing a signal,
M3.00 defective > inform Service
Check shielding gas supply (for machines with shielding gas monitoring)
Inverter error > inform Service
Separate the connection between the welding wire and casing or an earthed object
Error 9
(fast stop)
- - x Earth fault between welding wire and earth line
(Phoenix 330 only) x - - Fast cut-out triggered by BUSINT X11 or
RINT X12
Rectify error on robot
Error 10
(no arc)
Error 11
(no ign)
Error 14
(no DV)
Error 15
(DV2?)
Error 16
(VRD)
Error 17
(WF. Ov.)
- x - Arc break triggered by BUSINT X11 or
RINT X12
- x - Ignition fault after 5 s triggered by BUSINT X11 or
RINT X12
- x - Wire feeder not detected.
Control cable not connected.
Incorrect ID numbers assigned during operation with multiple wire feeders.
- x - Wire feeder 2 not detected.
Control cable not connected.
- - x VRD (open circuit voltage reduction error)
- x x Wire feed mechanism overcurrent detection
Check wire feeding
Check wire feeding
Check cable connections
Check assignment of ID numbers (see the
"Changing ID number of wire feeder" chapter)
Check cable connections
Inform Service
Check the wire feeding
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Rectifying faults
Error messages (power source)
Legend for categories (error reset) a) The error message will disappear once the error has been rectified. b) The error message can be reset by pressing a key button:
Welding machine control
RC1 / RC2
Key button
Expert
CarExpert / Progress (M3.11) alpha Q / Concept / Basic / Basic S / Synergic /
Synergic S / Progress (M3.71) Picomig 305 not possible c) The error message can only be reset by switching the machine off and on again.
The shielding gas error (Err 6) can be reset by pressing the "Welding parameters" key button.
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Rectifying faults
Resetting JOBs (welding tasks) to the factory settings
7.3
Resetting JOBs (welding tasks) to the factory settings
7.3.1
Resetting a single JOB
NOTE
All customised welding parameters that are stored will be replaced by the factory settings.
ENTER RESET
3 s
JOB-
LIST
3 s
JOB-
LIST
EXIT
3 s
Display m /m in
Figure 7-1
Setting/selection
Reset to factory settings
The RESET will be done after pressing the button.
The menu will be ended when no changes are done after 3 sec.
JOB-number (example)
The shown JOB will be set to ex works.
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Rectifying faults
Resetting JOBs (welding tasks) to the factory settings
7.3.2
Resetting all JOBs
NOTE
JOBs 1 –128 and 170–256 will be reset.
Custom JOBs 129 –169 are maintained.
ENTER
3 s
JOB-
LIST
RESET
3 s
JOB-
LIST
EXIT
3 s
Display m /m in
Figure 7-2
Setting/selection
Reset to factory settings
The RESET will be done after pressing the button.
The menu will be ended when no changes are done after 3 sec.
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Rectifying faults
Vent coolant circuit
7.4
Vent coolant circuit
NOTE
Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling.
To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)!
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Figure 7-3
87
Technical data
Phoenix Expert drive 4L
8 Technical data
NOTE
Performance specifications and guarantee only in connection with original spare and replacement parts!
8.1
Phoenix Expert drive 4L
Supply voltage 42 VAC/60 VDC
Max. welding current at 60% DC
Max. welding current at 100% DC
Wire feed speed
Factory-fit roller equipment
550 A
420 A
0.5 m/min to 24 m/min
1.0 + 1.2 mm (for steel wire)
4-roller (37 mm) Drive
Connecting the welding torch
Protection classification
Welding torch central connection (Euro)
IP 23
-25 °C to +40 °C Ambient temperature*
Dimensions L x W x H in mm
Weight
EMC class
Constructed to standards
690 x 300 x 410
15,1 kg
A
IEC 60974-1, -5, -10 /
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Accessories
General accessories
9 Accessories
NOTE
Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer.
9.1
General accessories
Type Designation Item no.
DM AR/MIX 35L/MIN
AK300
HOSE BRIDGE
Manometer pressure regulator
Wire spool adapter K300
Tube bridge
094-000009-00000
094-001803-00001
092-007843-00000
9.2
Remote control/connecting and extension cable
9.2.1
7-pole connection
Type
R40 7POL
R50 7POL
FRV 7POL 0.5 m
FRV 7POL 5 m
FRV 7POL 10 m
FRV 7POL 20 m
Designation
Remote control, 10 programs
Remote control, all welding machine functions can be set directly at the workplace
Extension/connecting cable
Extension/connecting cable
Extension/connecting cable
Extension/connecting cable
Extension/connecting cable
Item no.
090-008088-00000
090-008776-00000
092-000201-00004
092-000201-00003
092-000201-00000
092-000201-00001
092-000201-00007 FRV 7POL 25M
9.2.2
19-pole connection
Type
R10 19POL
RG10 19POL 5M
Item no.
090-008087-00000
090-008108-00000
R20 19POL
RA5 19POL 5M
RA10 19POL 10M
RA20 19POL 20M
RV5M19 19POLE 5M
RV5M19 19POLE 10M
RV5M19 19POLE 15M
RV5M19 19POLE 20M
Designation
Remote control
Remote control to set the wire speed and welding voltage correction
Program changeover remote control
Remote control e.g. connection cable
Remote control e.g. connection cable
Remote control e.g. connection cable
Extension cable
Extension cable
Extension cable
Extension cable
090-008263-00000
092-001470-00005
092-001470-00010
092-001470-00020
092-000857-00000
092-000857-00010
092-000857-00015
092-000857-00020
9.3
Options
Type
ON PS drive 4L T/P
ON WAKD2 4L/41L
ON WAKD 4L/41L
ON CMF drive 4L
Designation
Pivot support
Optional wheel assembly retrofit kit for drive 4L
Wheel assembly kit for DRIVE 4L
Optional retrofit crane suspension for drive 4L
Item no.
092-002112-00000
090-008151-00000
090-008169-00000
092-002483-00000
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Replaceable parts
Wire feed rollers
10 Replaceable parts
CAUTION
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.
10.1
Wire feed rollers
10.1.1
Wire feed rollers for steel wire
Type Designation
FE 2DR4R 0,6+0,8
FE 2DR4R 0,8+1,0
FE 2DR4R 0,9+1,2
Drive rollers, 37 mm, steel
Drive rollers, 37 mm, steel
Drive rollers, 37 mm, steel
Item no.
092-000839-00000
092-000840-00000
092-000841-00000
092-000842-00000
092-000843-00000
092-000844-00000
FE 2DR4R 1,0+1,2
FE 2DR4R 1,2+1,6
FE/AL 2GR4R
Drive rollers, 37 mm, steel
Drive rollers, 37 mm, steel
Pressure rollers, smooth, 37mm
10.1.2
Wire feed rollers for aluminium wire
Type Designation
AL 4ZR4R 0,8+1,0
AL 4ZR4R 1,0+1,2
AL 4ZR4R 1,2+1,6
AL 4ZR4R 2,4+3,2
Twin rollers, 37 mm, for aluminium
Twin rollers, 37 mm, for aluminium
Twin rollers, 37 mm, for aluminium
Twin rollers, 37 mm, for aluminium
10.1.3
Wire feed rollers for cored wire
Type Designation
ROE 2DR4R 0,8/0,9+0,8/0,9 Drive rollers, 37 mm, cored wire
ROE 2DR4R 1,0/1,2+1,4/1,6 Drive rollers, 37 mm, cored wire
ROE 2DR4R 1,4/1,6+2,0/2,4 Drive rollers, 37 mm, cored wire
ROE 2DR4R 2,8+3,2 Drive rollers, 37 mm, cored wire
ROE 2GR4R Pressure rollers, knurled, 37mm
Item no.
092-000869-00000
092-000848-00000
092-000849-00000
092-000870-00000
Item no.
092-000834-00000
092-000835-00000
092-000836-00000
092-000837-00000
092-000838-00000
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Replaceable parts
Wire feed rollers
10.1.4
Conversion sets
Type Designation
URUE VERZ>UNVERZ FE/AL
4R
Conversion kit, 37mm, 4-roller drive on non-toothed rollers (steel/aluminium)
URUE AL 4ZR4R 0,8+1,0
URUE AL 4ZR4R 1,0+1,2
URUE AL 4ZR4R 1,2+1,6
Item no.
092-000845-00000
Conversion kit, 37mm, 4-roller drive for aluminium 092-000867-00000
Conversion kit, 37mm, 4-roller drive for aluminium 092-000846-00000
Conversion kit, 37mm, 4-roller drive for aluminium 092-000847-00000
URUE AL 4ZR4R 2,4+3,2
URUE ROE 2DR4R
0,8/0,9+0,8/0,9
Conversion kit, 37mm, 4-roller drive for aluminium
Conversion kit, 37mm, 4-roller drive for cored wire
092-000868-00000
092-000830-00000
URUE ROE 2DR4R
1,0/1,2+1,4/1,6
URUE ROE 2DR4R
1,4/1,6+2,0/2,4
Conversion kit, 37mm, 4-roller drive for cored wire
Conversion kit, 37mm, 4-roller drive for cored wire
092-000831-00000
092-000832-00000
URUE ROE 2DR4R 2,8+3,2 Conversion kit, 37mm, 4-roller drive for cored wire 092-000833-00000
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Figure 10-1
91
Appendix A
JOB-List
11 Appendix A
11.1
JOB-List
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JOB-List
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Appendix A
JOB-List
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Appendix A
JOB-List
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Appendix A
JOB-List
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Appendix A
JOB-List
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Appendix A
JOB-List
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Appendix A
JOB-List
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Appendix A
JOB-List
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12 Appendix B
12.1
Overview of EWM branches
Appendix B
Overview of EWM branches
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Table of contents
- 3 Contents
- 6 Safety instructions
- 6 Notes on the use of these operating instructions
- 7 Explanation of icons
- 8 General
- 12 Transport and installation
- 13 Ambient conditions
- 13 In operation
- 13 Transport and storage
- 14 Intended use
- 14 Applications
- 14 MIG/MAG standard welding
- 14 forceArc
- 14 rootArc
- 14 MIG/MAG pulse welding
- 14 forceArc puls
- 14 rootArc puls
- 14 TIG (Liftarc) welding
- 14 MMA welding
- 14 Air arc gouging
- 15 Use and operation solely with the following machines
- 16 Documents which also apply
- 16 Warranty
- 16 Declaration of Conformity
- 16 Welding in environments with increased electrical hazards
- 16 Service documents (spare parts and circuit diagrams)
- 16 Calibration/Validation
- 17 – quick overview
- 17 Front view
- 18 Rear view
- 19 Inside view
- 20 – Operating elements
- 22 – Concealed operating elements
- 24 Design and function
- 24 General
- 25 Installation
- 26 Welding torch cooling system
- 26 General
- 26 List of coolants
- 27 Notes on the installation of welding current leads
- 28 Intermediate hose package connection
- 29 Shielding gas supply (shielding gas cylinder for welding machine)
- 29 Gas test
- 29 “Rinse hose package” function
- 29 Setting the shielding gas quantity
- 30 MIG/MAG welding
- 30 Welding torch connection
- 32 Wire feed
- 32 Open the protective flap of the wire feeder
- 32 Inserting the wire spool
- 33 Changing the wire feed rollers
- 34 Inching the wire electrode
- 36 Spool brake setting
- 37 Definition of MIG/MAG welding tasks
- 37 Welding task selection
- 39 Burn-back
- 40 MIG/MAG operating point
- 40 Selecting the display unit
- 40 Operating point setting using material thickness
- 41 Arc length correction setting
- 41 Accessory components for operating point setting
- 41 MIG/MAG welding data display
- 42 Conventional MIG/MAG Welding (GMAW non synergic)
- 42 Setting the operating point (welding output)
- 43 forceArc / forceArc puls
- 44 rootArc/rootArc puls
- 45 MIG/MAG program sequence ("Program steps" mode)
- 45 control M
- 46 MIG/MAG overview of parameters, M
- 47 Main program A mode
- 47 MIG/MAG automatic cut-out
- 48 Standard MIG/MAG torch
- 48 MIG/MAG special-torches
- 48 Program- and Up- / down operation
- 49 MIG/MAG Push/Pull welding torch
- 49 Pin assignment
- 50 Switching between Push/Pull and intermediate drive
- 51 Expert menu (MIG/MAG)
- 51 Selection
- 53 TIG welding
- 53 Welding torch connection
- 54 Welding task selection
- 55 TIG arc ignition
- 55 Liftarc ignition
- 55 TIG automatic cut-out
- 56 TIG arc ignition
- 56 Liftarc ignition
- 56 Pulses, function sequences
- 56 Explanation of signs and functions
- 60 MMA welding
- 60 Welding task selection
- 60 Setting using the stick electrode diameter
- 61 Arcforce
- 61 Hotstart
- 62 Remote control
- 62 Interfaces for automation
- 63 Remote control connection socket, 19-pole
- 64 Special parameters (advanced settings)
- 65 Selecting, changing and saving parameters
- 67 Reset to factory settings
- 68 The special parameters in detail
- 75 Machine configuration menu
- 75 Selecting, changing and saving parameters
- 77 Matching the cable resistance
- 78 Power-saving mode
- 79 Maintenance, care and disposal
- 79 General
- 79 Maintenance work, intervals
- 79 Daily maintenance tasks
- 79 Visual inspection
- 79 Functional test
- 80 Monthly maintenance tasks
- 80 Visual inspection
- 80 Functional test
- 80 Annual test (inspection and testing during operation)
- 80 Maintenance work
- 81 Disposing of equipment
- 81 Manufacturer's declaration to the end user
- 81 Meeting the requirements of RoHS
- 82 Rectifying faults
- 82 Checklist for rectifying faults
- 83 Error messages (power source)
- 85 Resetting JOBs (welding tasks) to the factory settings
- 85 Resetting a single JOB
- 86 Resetting all JOBs
- 87 Vent coolant circuit
- 88 Technical data
- 88 Phoenix Expert drive 4L
- 89 Accessories
- 89 General accessories
- 89 Remote control/connecting and extension cable
- 89 7-pole connection
- 89 19-pole connection
- 89 Options
- 90 Replaceable parts
- 90 Wire feed rollers
- 90 Wire feed rollers for steel wire
- 90 Wire feed rollers for aluminium wire
- 90 Wire feed rollers for cored wire
- 91 Conversion sets
- 92 Appendix A
- 92 JOB-List
- 101 Appendix B
- 101 Overview of EWM branches