EWM Taurus 355 Synergic S HP MM TKM Operating Instructions Manual

Operating instructions

Welding machine

Taurus 355 Synergic S HP MM TKM

099-005407-EW501 31.03.2015

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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.

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.

The content of this document has been prepared and reviewed with all reasonable care. The information provided is subject to change, errors excepted.

Contents

Notes on the use of these operating instructions

1 Contents

1 Contents .................................................................................................................................................. 3

2 Safety instructions ................................................................................................................................. 6

2.1

Notes on the use of these operating instructions .......................................................................... 6

2.2

Explanation of icons ....................................................................................................................... 7

2.3

General .......................................................................................................................................... 8

2.4

Transport and installation ............................................................................................................ 12

2.4.1

Ambient conditions ....................................................................................................... 13

2.4.1.1

In operation ................................................................................................... 13

2.4.1.2

Transport and storage ................................................................................... 13

3 Intended use ......................................................................................................................................... 14

3.1

Applications .................................................................................................................................. 14

3.1.1

MIG/MAG standard welding ......................................................................................... 14

3.1.1.1

forceArc ......................................................................................................... 14

3.1.1.2

rootArc ........................................................................................................... 14

3.1.1.3

MIG/MAG cored wire welding ....................................................................... 14

3.1.2

TIG (Liftarc) welding ..................................................................................................... 14

3.1.3

MMA welding ................................................................................................................ 14

3.1.3.1

Air arc gouging .............................................................................................. 14

3.2

Documents which also apply ....................................................................................................... 15

3.2.1

Warranty ....................................................................................................................... 15

3.2.2

Declaration of Conformity ............................................................................................. 15

3.2.3

Welding in environments with increased electrical hazards ......................................... 15

3.2.4

Service documents (spare parts and circuit diagrams) ................................................ 15

3.2.5

Calibration/Validation ................................................................................................... 15

4 Machine description – quick overview .............................................................................................. 16

4.1

Front view .................................................................................................................................... 16

4.2

Rear view ..................................................................................................................................... 18

4.2.1

Operating elements in the machine .............................................................................. 20

4.3

Machine control

– Operating elements ........................................................................................ 22

4.3.1

Functional sequence .................................................................................................... 24

5 Design and function ............................................................................................................................. 25

5.1

General ........................................................................................................................................ 25

5.2

Installation .................................................................................................................................... 26

5.2.1

Protective flap, welding machine control ...................................................................... 27

5.3

Machine cooling ........................................................................................................................... 27

5.4

Workpiece lead, general .............................................................................................................. 27

5.5

Notes on the installation of welding current leads ....................................................................... 28

5.6

Mains connection ......................................................................................................................... 30

5.6.1

Mains configuration ...................................................................................................... 30

5.7

Welding torch cooling system ...................................................................................................... 31

5.7.1

Welding torch cooling unit connection .......................................................................... 31

5.8

Shielding gas supply (shielding gas cylinder for welding machine) ............................................. 32

5.8.1

Gas test ........................................................................................................................ 33

5.8.2

Rinse hose package function ....................................................................................... 33

5.8.3

Setting the shielding gas quantity ................................................................................. 33

5.9

Welding torch holder .................................................................................................................... 34

5.10

MIG/MAG welding ........................................................................................................................ 35

5.10.1

Welding torch and workpiece line connection .............................................................. 35

5.10.2

Wire feed ...................................................................................................................... 37

5.10.2.1

Open the protective flap of the wire feeder ................................................... 37

5.10.2.2

Inserting the wire spool ................................................................................. 37

5.10.2.3

Changing the wire feed rollers ...................................................................... 38

5.10.2.4

Inching the wire electrode ............................................................................. 40

5.10.2.5

Spool brake setting ....................................................................................... 42

5.10.3

Definition of MIG/MAG welding tasks ........................................................................... 43

5.10.4

Welding task selection .................................................................................................. 43

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Contents


5.10.4.1

Basic welding parameters ............................................................................. 43

5.10.4.2

Operating mode ............................................................................................. 43

5.10.4.3

Choke effect / dynamics ................................................................................ 44

5.10.4.4

superPuls ...................................................................................................... 44

5.10.4.5

Burn-back ...................................................................................................... 45

5.10.5

MIG/MAG operating point ............................................................................................. 46

5.10.5.1

Selecting the display unit............................................................................... 46

5.10.5.2

Operating point setting using material thickness .......................................... 46

5.10.5.3

Arc length correction setting .......................................................................... 47

5.10.5.4

Accessory components for operating point setting ....................................... 47

5.10.6

MIG/MAG welding data display .................................................................................... 47

5.10.6.1

forceArc ......................................................................................................... 48

5.10.6.2

rootArc ........................................................................................................... 49

5.10.7

MIG/MAG functional sequences / operating modes ..................................................... 50

5.10.7.1

Explanation of signs and functions ................................................................ 50

5.10.8

MIG/MAG program sequence ("Program steps" mode) ............................................... 60

5.10.8.1

Selection of the program sequence parameter ............................................. 60

5.10.8.2

MIG/MAG overview of parameters ................................................................ 61

5.10.8.3

Example, tack welding (non-latched) ............................................................ 62

5.10.8.4

Example, aluminium tack welding (non-latched special) .............................. 62

5.10.8.5

Example, aluminium welding (latched special) ............................................. 63

5.10.8.6

Example, visible seams (latched super pulse) .............................................. 64

5.10.9

Main program A mode .................................................................................................. 65

5.10.9.1

Selecting parameters (program A) ................................................................ 67

5.10.10

MIG/MAG automatic cut-out ......................................................................................... 67

5.10.11

Standard MIG/MAG torch ............................................................................................. 68

5.10.12

MIG/MAG special-torches............................................................................................. 68

5.10.12.1

Program- and Up- / down operation .............................................................. 68

5.10.12.2

Switching between Push/Pull and intermediate drive ................................... 68

5.10.13

Expert menu (MIG/MAG) .............................................................................................. 69

5.10.13.1

Selection ........................................................................................................ 69

5.11

TIG welding .................................................................................................................................. 71

5.11.1

Welding torch and workpiece line connection .............................................................. 71

5.11.2


5.11.3

Welding current setting ................................................................................................. 72

5.11.4

TIG arc ignition ............................................................................................................. 72

5.11.4.1

Liftarc ignition ................................................................................................ 72

5.11.5

Function sequences/operating modes .......................................................................... 73

5.11.5.1

Explanation of signs and functions ................................................................ 73

5.11.5.2

TIG automatic cut-out .................................................................................... 76

5.11.6

TIG program sequence ("Program steps" mode) ......................................................... 77

5.12

MMA welding ................................................................................................................................ 78

5.12.1

Connecting the electrode holder and workpiece lead .................................................. 78

5.12.2


5.12.3

Welding current setting ................................................................................................. 79

5.12.4

Arcforce......................................................................................................................... 79

5.12.5

Hotstart ......................................................................................................................... 80

5.12.6

Antistick......................................................................................................................... 80

5.12.7

Parameter overview ...................................................................................................... 80

5.13

Remote control ............................................................................................................................. 81

5.14

Interfaces for automation ............................................................................................................. 81

5.14.1

Remote control connection socket, 19-pole ................................................................. 82

5.15

PC Interfaces ............................................................................................................................... 83

5.16

Protecting welding parameters from unauthorised access .......................................................... 83

5.17

Special parameters (advanced settings) ...................................................................................... 83

5.17.1

Selecting, changing and saving parameters................................................................. 84

5.17.1.1

Reset to factory settings ................................................................................ 86

5.17.1.2

The special parameters in detail ................................................................... 87

5.18

Machine configuration menu ........................................................................................................ 95

5.18.1

Selecting, changing and saving parameters................................................................. 95

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Contents


5.18.2

Adjusting the cable resistance ...................................................................................... 97

5.18.3

Power-saving mode (Standby) ..................................................................................... 98

6 Maintenance, care and disposal ......................................................................................................... 99

6.1

General ........................................................................................................................................ 99

6.2

Maintenance work, intervals ........................................................................................................ 99

6.2.1

Daily maintenance tasks .............................................................................................. 99

6.2.1.1

Visual inspection ........................................................................................... 99

6.2.1.2

Functional test ............................................................................................... 99

6.2.2

Monthly maintenance tasks ........................................................................................ 100

6.2.2.1

Visual inspection ......................................................................................... 100

6.2.2.2

Functional test ............................................................................................. 100

6.2.3

Annual test (inspection and testing during operation) ................................................ 100

6.3

Disposing of equipment ............................................................................................................. 101

6.3.1

Manufacturer's declaration to the end user ................................................................ 101

6.4

Meeting the requirements of RoHS ........................................................................................... 101

7 Rectifying faults ................................................................................................................................. 102

7.1

Checklist for rectifying faults ...................................................................................................... 102

7.2

Error messages .......................................................................................................................... 103

7.3

Error messages (power source) ................................................................................................ 103

7.4

Resetting JOBs (welding tasks) to the factory settings ............................................................. 105

7.4.1

Resetting a single JOB ............................................................................................... 105

7.4.2

Resetting all JOBs ...................................................................................................... 106

8 Technical data .................................................................................................................................... 107

8.1

Taurus 355 Synergic S .............................................................................................................. 107

9 Accessories ........................................................................................................................................ 108

9.1

General accessories .................................................................................................................. 108

9.2

Remote control/connecting and extension cable ....................................................................... 108

9.2.1

7-pole connection ....................................................................................................... 108

9.2.2

19-pole connection ..................................................................................................... 108

9.3

Options ....................................................................................................................................... 109

9.4

Computer communication .......................................................................................................... 109

10 Replaceable parts .............................................................................................................................. 110

10.1

Wire feed rollers ......................................................................................................................... 110

10.1.1

Wire feed rollers for steel wire .................................................................................... 110

10.1.2

Wire feed rollers for aluminium wire ........................................................................... 111

10.1.3

Wire feed rollers for cored wire .................................................................................. 111

10.1.4

Wire guide .................................................................................................................. 111

11 Appendix A ......................................................................................................................................... 112

11.1

JOB-List ..................................................................................................................................... 112

12 Appendix B ......................................................................................................................................... 113

12.1

Overview of EWM branches ...................................................................................................... 113

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Safety 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.

Special technical points which users must observe.

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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2.2 Explanation of icons

Symbol Description

Special technical points which users must observe.

Correct

Wrong

Press

Do not press

Press and keep pressed

Turn

Switch

Switch off machine

Switch on machine

ENTER (enter the menu)

NAVIGATION NAVIGATION (Navigating in the menu)


Explanation of icons

EXIT

4 s

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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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 6 Maintenance, care and disposal 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

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!

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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General

WARNING

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!

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!

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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General

CAUTION

Obligations of the operator!

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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General

CAUTION

EMC Machine Classification

In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes - See 8 Technical data chapter:

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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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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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

3.1.1.3 MIG/MAG cored wire welding

Welding with cored wire electrodes consisting of a metal casing and a powder core.

As with MIG/MAG standard welding, the arc is protected from the atmosphere by shielding gas. The gas is supplied either externally (gas shielded cored wires) or produced in the arc by means of the powder core (self-shielding cored wires).

3.1.2 TIG (Liftarc) welding

TIG welding process with arc ignition by means of workpiece contact.

3.1.3 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.

3.1.3.1 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

Documents which also apply

3.2 Documents which also apply

3.2.1 Warranty

For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com

!

3.2.2 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.

3.2.3 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.

3.2.4 Service documents (spare parts and circuit diagrams)

DANGER





Original copies of the circuit diagrams are enclosed with the unit.

Spare parts can be obtained from the relevant authorised dealer.

3.2.5 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

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Front view

Item Symbol Description 0

1 Transport bar

2

3

4

5

6

Carrying handle

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.

Wire spool inspection window

Check wire supply

Slide latch, lock for the protective cap

Machine control- See 4.3 Machine control

– Operating elements chapter

7

8

Cooling air inlet

Welding torch connection (Euro or Dinse torch connector)

Welding current, shielding gas and torch trigger integrated

Machine feet 9

10 Park socket, polarity selection plug

Retainer for the polarity selection plug in MMA mode or for transport.

11

12

19-pole connection socket (analogue)

For connecting analogue accessory components (remote control, welding torch control lead, etc.)

Connection socket, "+" welding current

• MIG/MAG cored wire welding:

Workpiece connection

• TIG welding:

• MMA welding:



13

15

"-" welding current connection socket

• MIG/MAG welding:


• TIG welding:

• MMA welding:

Welding current connection for welding torch electrode holder connection

14 Welding current cable, polarity selection

Welding current to Euro torch connector /torch, for polarity selection

•

MIG/MAG:

Connection socket for “+” welding current

• Selfshielding flux cored wire/TIG: Connection socket, “-” welding current

•

MMA: Park socket

▼ optional, factory-fitted

▼

Key switch for protection against unauthorised use

Position “1” > changes possible,

Position “0” > changes not possible.

- See 5.16 Protecting welding parameters from unauthorised access chapter

▲ optional, factory-fitted

▲

16 Protective cap

- See 5.2.1 Protective flap, welding machine control chapter

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Rear view

4.2 Rear view

Figure 4-2

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Rear view

3

4

5


1 Main switch, machine on/off

2 Connecting nipple G¼, shielding gas connection

Cooling air inlet

Cooling air outlet

External wire feed inlet

Pre-cut casing inlet for external wire feed.

6

7

8

9

Mains connection cable

- See 5.6 Mains connection chapter

7-pole connection socket (digital)

For connecting digital accessory components (documentation interface, robot interface or remote control, etc.).

8-pole connection socket

Cooling unit control lead

4-pole connection socket

Cooling unit voltage supply

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Rear view

4.2.1 Operating elements in the machine

Figure 4-3

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Rear view


1

2

3

Key button, automatic cutout

Wire feed motor supply voltage fuse press to reset a triggered fuse

Welding torch function changeover switch (special welding torch required)

Changing over programs or JOBs

Infinite adjustment of welding performance.

PC interface, serial (D-Sub connection socket, 9-pole)

4 Wire spool holder

5 Wire feed unit

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Machine control

– Operating elements

4.3 Machine control – Operating elements

22

Figure 4-4


1 Functional sequence - See 4.3.1 Functional sequence chapter

2

3

4

5

6

Push-button, welding task selection (JOB)

Select the welding task using the welding task list (JOB-LIST) (not applicable for

Phoenix Expert). The list can be found inside the protective cap of the wire feed mechanism and in the appendix to these operating instructions.

Display, left

Welding current, material thickness, wire speed, hold values

Push-button, parameter selection left/power-saving mode

AMP Welding current

Material thickness

Wire feed speed

Hold After welding, the values used last are shown from the main program. The signal light is illuminated.

STBY Press for 2 s to put machine into power-saving mode.

To reactivate, activate one of the operating elements.

Display, JOB

Shows the currently selected welding task (JOB number).

Welding parameter setting, rotary dial

For setting the welding performance, for selecting the JOB (welding task) and for setting other welding parameters.

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Machine control



7

8

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

Push-button, throttling effect (arc dynamics)

9

Arc is harder and more narrow

Arc is softer and wider

Standard MIG/MAG welding signal light

10

11

12

13

14

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).

Button, Parameter selection (right)

VOLT Welding voltage

Prog Program number kW Welding performance display

Gas flow quantity (optional)

Display, right

Welding voltage, program number, motor current (wire feed mechanism)

Gas test / rinse button

• Gas test:

For setting the shielding gas quantity

• Rinse: For rinsing longer hose packages

- See 5.8 Shielding gas supply (shielding gas cylinder for welding machine) chapter

Push-button, wire inching/motor current (wire feed mechanism)

- See 5.10.2.4 Inching the wire electrode chapter

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Machine control


4.3.1 Functional sequence

24

Figure 4-5


1 Select welding parameters button

This button is used to select the welding parameters depending on the welding process and operating mode used.

2

3

4

5

6

7

Signal light, gas pre-flow time

Setting range 0.0 s to 20.0 s

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 sec Signal light, start time

Setting range, absolute 0.0 s to 20.0 s (0.1 s increments) sec 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)

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 sec 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

8

9

10

11

12

13

14

Signal light, reduced main program (P

B

)


A

• Correction of the arc length -9.9 V to +9.9 V sec 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. sec Signal light, slope time program P

A

(or P

B

) to end program P

END


Signal light, end program (P

END

)


A

• Correction of the arc length -9.9 V to +9.9 V sec Signal light, duration of end program P

END


Signal light, gas post-flow time

Setting range 0.0 s to 20.0 s

Super- puls

Signal lamp, super pulse function

Lights up when the super pulse function is active.

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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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Installation

CAUTION

Damage due to incorrect connection!

Accessory components and the power source itself can be damaged by incorrect connection!


• 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!

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 9 Accessories chapter.

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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5.2.1 Protective flap, welding machine control


Machine cooling

Figure 5-1


1 Protective cap

2 Lid

3 Bracket, protective cap

• Push the right-hand bracket of the protective cap to the right and remove the protective cap.

5.3 Machine cooling

To obtain an optimal duty cycle from the power components, the following precautions should be observed:

• Ensure that the working area is adequately ventilated.

•

Do not obstruct the air inlets and outlets of the machine.

•

Do not allow metal parts, dust or other objects to get into the machine.

5.4 Workpiece lead, general

CAUTION

Risk of burns due to incorrect connection of the workpiece lead!

Paint, rust and dirt on the connection restrict the power flow and may lead to stray welding currents.

Stray welding currents may cause fires and injuries!

• Clean the connections!

• Fix the workpiece lead securely!

• Do not use structural parts of the workpiece as a return lead for the welding current!

• Take care to ensure faultless power connections!

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Notes on the installation of welding current leads

5.5 Notes on the installation of welding current leads

Incorrectly installed welding current leads can cause faults in the arc (flickering).

Lay the workpiece lead and hose package of power sources without HF igniter (MIG/MAG) for as long and as close as possible in parallel.

Lay the workpiece lead and hose package of power sources with HF igniter (TIG) for as long as possible in parallel with a distance of 20 cm to avoid HF sparkover.

Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences

Always keep leads as short as possible! For optimum welding results max. 30 m (welding lead + intermediate hose package + torch lead).

28

Figure 5-2

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Notes on the installation of welding current leads

Use an individual welding lead to the workpiece for each welding machine!

Figure 5-3

Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops!

Always keep leads as short as possible!

Lay any excess cable lengths in meanders.

Figure 5-4

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Mains connection

5.6 Mains connection

DANGER

Hazard caused by improper mains connection!

An improper mains connection can cause injuries or damage property!

• Only use machine with a plug socket that has a correctly fitted protective conductor.

• If a

mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations!

• Mains plug, socket and lead must be checked regularly by an electrician!

• When operating the generator always ensure it is earthed as stated in the operating instructions. The resulting network has to be suitable for operating devices according to protection class 1.

5.6.1 Mains configuration

The machine may be connected to:

• a three-phase system with four conductors and an earthed neutral conductor

• a three-phase system with three conductors of which any one can be earthed, e.g. the outer conductor

Figure 5-5

Legend

Item

L1

L2

L3

N

PE

Designation

Outer conductor 1

Outer conductor 2

Outer conductor 3

Neutral conductor

Protective conductor

Colour code brown black grey blue green-yellow

CAUTION

Operating voltage - mains voltage!

The operating voltage shown on the rating plate must be consistent with the mains voltage, in order to avoid damage to the machine!

• - See 8 Technical data chapter!

• Insert mains plug of the switched-off machine into the appropriate socket.

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Welding torch cooling system

5.7 Welding torch cooling system

5.7.1 Welding torch cooling unit connection

Please note the relevant documentation of the accessory components.

Figure 5-6


1 4-pole connection socket

Cooling unit voltage supply

2 8-pole connection socket

Cooling unit control lead

Cooling unit 3

• Insert and lock the 8-pole control lead plug on the cooling unit into the 8-pole connection socket on the welding machine.

• Insert and lock the 4-pole supply plug on the cooling unit into the 4-pole connection socket on the welding machine.

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Shielding gas supply (shielding gas cylinder for welding machine)

5.8 Shielding gas supply (shielding gas cylinder for welding machine)

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!

CAUTION

Faults in the shielding gas supply.

An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results. In addition, a blocked shielding gas supply may result in the welding torch being destroyed.

• Always re-fit the yellow protective cap when not using the shielding gas connection.

• All shielding gas connections must be gas tight.

Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to expel any dirt.

Figure 5-7


1 Pressure regulator

2 Shielding gas cylinder

3 Output side of the pressure regulator

4 Cylinder valve

• Place the shielding gas cylinder into the relevant cylinder bracket.

• Secure the shielding gas cylinder using a securing chain.

• Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight.

• Tighten gas hose on pressure regulator to be gas tight.

• Fasten the gas hose to the shielding gas connecting nipple at the back of the machine using the crown nut.

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Shielding gas supply (shielding gas cylinder for welding machine)

5.8.1 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.

5.8.2 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.

5.8.3 Setting the shielding gas quantity

Welding process Recommended shielding gas quantity

MAG welding

MIG brazing

MIG welding (aluminium)

TIG

Wire diameter x 11.5 = l/min

Wire diameter x 11.5 = l/min

Wire diameter x 13.5 = l/min (100 % argon)

Gas nozzle diameter in mm corresponds to l/min gas throughput

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

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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Welding torch holder

5.9 Welding torch holder

The item described in the following is part of the machine´s scope of delivery.

Figure 5-8


1 Crossmember of the transport handle

2 Torch holder

3 Fan-type lock washers

4 Fixing screws (x 4)

• Use the mounting screws to screw the torch holder onto the crossmember of the transport handle.

• Insert the welding torch into the welding torch holder as shown.

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MIG/MAG welding

5.10 MIG/MAG welding

5.10.1 Welding torch and workpiece line connection

On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a steel liner. Conversion is necessary if a welding torch with a liner is used!

• Operate welding torches with a liner > with a guide tube.

• Operate welding torches with a steel liner > with a capillary tube.

Depending on the wire electrode diameter or type, either a steel liner or liner with the correct inner diameter must be inserted in the torch!

Recommendation:

• Use a steel liner when welding hard, unalloyed wire electrodes (steel).

• Use a chrome nickel liner when welding hard, high-alloy wire electrodes (CrNi).

• Use a liner to weld or braze soft wire electrodes, high-alloy wire electrodes or aluminium materials.

Preparation for connecting welding torches with a liner:

• Push forward the capillary tube on the wire feed side in the direction of the Euro torch connector and remove it there.

• Insert the liner guide tube from the Euro torch connector side.

• Carefully insert the welding torch connector with as yet too long a liner into the Euro torch connector and secure with a crown nut.

• Cut off the liner with a liner cutter just before the wire feed roller.

• Loosen the welding torch connector and remove.

• Carefully chamfer the cut off end of the liner with a liner sharpener and sharpen.

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MIG/MAG welding

Some wire electrodes (e.g. self-shielding cored wire) are welded using negative polarity. In this case, the welding current lead should be connected to the "-" welding current socket, and the workpiece lead should be connected to the "+" welding current socket. Observe the information from the electrode manufacturer!

Figure 5-9


1 Welding torch

2

3

4

5

6

7

Welding torch hose package



19-pole connection socket (analogue)

Connection for welding torch control lead

Welding current cable, polarity selection

Welding current to central connection/torch. Permits polarity selection for MIG/MAG welding.

•

Standard applications > Connection for "+" welding current connection socket


•

MIG/MAG welding: Workpiece connection

Workpiece

• Insert the central plug for the welding torch into the central connector and screw together with crown nut.

• Insert the plug on the workpiece lead into the "-" welding current connection socket and lock.

• Welding current lead, insert polarity selection into the "+" welding current connection socket and lock.

Where applicable:

• Insert the welding torch control cable into the 19-pole connection socket and lock (MIG/MAG torches with additional control cables only).

• 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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MIG/MAG welding

5.10.2 Wire feed

5.10.2.1 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.

5.10.2.2 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.

Standard D300 wire spool holder can be used. Adapters - See 9 Accessories chapter are required when using standardised basket coils (DIN 8559).

Figure 5-10


1 Carrier pin

For fixing the wire spool

2 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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MIG/MAG welding

5.10.2.3 Changing the wire feed rollers

Figure 5-11


1 Tommy

The tommy is used to secure the closure brackets of the wire feed rollers.

2

3

4

Closure bracket

The closure brackets are used to secure the wire feed rollers.

Feed roll tensioner

Fixing the clamping unit and setting the pressure.

Clamping unit

5 Wire feed roller see the Wire feed roller overview table

• Rotate the tommy by 90° clockwise or anti-clockwise (tommy locks into place).

• Fold the closure brackets outwards by 90°.

• Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip upwards).

• Remove the wire feed rollers from the roller support.

• Select new wire feed rollers accoridng to the Wire feed roller overview table and reassemble the wire feed mechanism in reverse order.

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MIG/MAG welding

Unsatisfactory welding results due to faulty wire feeding!

The wire feed rollers must be suitable for the diameter of the wire and the material. The wire feed rollers are colour-coded to facilitate distinction (see the Wire feed roller overview table).

Wire feed roller overview table

Material Diameter



mm



inch

Colour code Groove form

Steel

Stainless steel

Brazing

Aluminium

0.8

0.9/1.0

1.2

1.4

1.6

2.0

2.4

2.8

3.2

0.8

0.9/1.0

1.2

1.6

2.0

2.4

2.8

.030

.035/.040

045

052

060

.080

.095

.110

.125

.030

.035/.040

.045

.060

.080

.095

.110 monochrome bichrome purple white blue red black grey brown

Light green purple white blue white blue red green black grey brown

Light green

- yellow

V-groove

U-groove

Flux cored wire

3.2

0.8

0.9

1.0

1.2

1.4

1.6

2.0

2.4

.125

.030

.035

.040

.045

.052

.060

.080

.095

- See 10 Replaceable parts chapter bichrome red green black grey brown orange

V-groove, knurled

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MIG/MAG welding

5.10.2.4 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!

The inching speed is infinitely adjustable by simultaneously pressing the wire inching pushbutton and turning the wire speed rotary knob. The left display shows the wire feed speed selected, the right display shows the current motor current of the wire feed mechanism.

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MIG/MAG welding

Figure 5-12


1 Welding wire

2 Wire feed nipple

3 Guide tube

4 Adjusting nut

• Extend and lay out the torch hose package.

• Carefully unwind the welding wire from the wire spool and insert through the wire feed nipples up to the wire feed rollers.

• Press the inching push-button (the drive catches the welding wire and automatically guides it to the welding torch outlet).

A prerequisite for the automatic inching process is the correct preparation of the wire guide, especially in the capillary and wire guide tube area .

• Set the pressure at the feed roll tensioner adjusting nuts depending on the welding consumable. The pressure must be set for each side (left/right) separately. Setting values see table:

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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MIG/MAG welding

5.10.2.5 Spool brake setting

Figure 5-13


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.

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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MIG/MAG welding

5.10.3 Definition of MIG/MAG welding tasks

This range of machines feature 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 .

• Simple JOB selection from a list of pre-defined JOBs (sticker on the machine).

• The required process parameters are calculated by the system depending on the operating point specified (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.

5.10.4 Welding task selection

5.10.4.1 Basic welding parameters

• Select JOB (welding task) with JOB list.

The JOB list sticker can be found on the inside of the protective flap of the wire feeder.

You can only change the JOB number when no welding current is flowing.

Operating element

Action Result Display

Select JOB list

1 x

Set JOB number.

Wait 3s until the setting has been adopted.

5.10.4.2 Operating mode


Action Result Display n x

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

No change

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MIG/MAG welding

5.10.4.3 Choke effect / dynamics

ENTER EXIT

3 s

Figure 5-14

Display Setting/selection

Dynamics setting

40: Arc harder and narrower

-40: Arc softer and wider

5.10.4.4 superPuls

In superPuls mode, the program toggles from main program (PA) to reduced main program (PB). This function is used e.g. in thin sheet welding to accurately reduce the heat input or weld vertical-up welds without weaving. superPuls in combination with EWM welding processes offers many possibilities.

Welding performance can be represented as average value (ex works) or solely as program A value. If the average value display is activated the signal lights of the main (PA) and reduced main program (PB) are illuminated simultaneously. The display variants can be changed using special parameter P19, - See

5.17 Special parameters (advanced settings) chapter.

ENTER EXIT

3 s


Selects superPuls

Switches function on or off.

Switch on

Switching on machine function

Switch off

Switching off machine function

Figure 5-15

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5.10.4.5 Burn-back

ENTER

3 s

EXIT

3 s


MIG/MAG welding

Display

Figure 5-16

Setting/selection menu burn back

Set burn back

Parameter setting (setting range 0 to 499)

Back-burn set too high: large drops developing on the wire electrode result in poor ignition properties or the wire electrode sticking to the welding nozzle.

Back-burn set too low: Wire electrode sticks in the molten pool

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MIG/MAG welding

5.10.5 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.

5.10.5.1 Selecting the display unit

Figure 5-17

The operating point (welding performance) can be displayed as the welding current, material thickness or wire speed.


Action Result

Switching the display between:

Welding current n x

Material thickness

Wire speed

Application example

Aluminium is to be welded.

• Material = AlMg,

• Gas = Ar 100%,

• Wire diameter = 1.2 mm

The correct wire speed is not known and is to be determined.

• Select the appropriate JOB (- See 11.1 JOB-List chapter)

• Switch to the material thickness display

• Set the material thickness as appropriate (e.g. 5 mm)

• Switch to the wire speed display

The resulting wire speed will be shown (e.g. 8.4 m/min).

5.10.5.2 Operating point setting using material thickness

Given below is a description of the setting work via the wire speed parameters as an example of operating point setting.



Increase or reduce welding performance via the wire speed parameter.

Display example: 10.5 m/min

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5.10.5.3 Arc length correction setting

The arc length can be corrected as follows.



"Arc length correction" setting

(Display example: -0.9V, setting range -9.9 V to +9.9 V)

5.10.5.4 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 interface for automated welding required – not possible for all machines in this series!)

For an overview of the accessory components See the operating instructions for the machine in question for a more detailed description of the individual machines and their functions.

- See 9 Accessories chapter

5.10.6 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 5-18

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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MIG/MAG welding

5.10.6.1 forceArc

Heat-reduced, directionally stable and powerful arc with deep penetration for the upper power range.

Figure 5-19

• 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%

JOB

190

0.8

JOB

17.0 254

1

189

-

17.0

-

179

251

Wire Ø (mm)

12.0

12.0

12.0

JOB

255

180

252

1.2

9.5

JOB

1.6

256 7.0

9.5 181

12.0 253

6.0

6.0

You can make use of these properties after selecting the forceArc process- See 5.10.4 Welding task selection 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!

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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5.10.6.2 rootArc

Short arc with easy weld modelling capabilities for effortless gap bridging and positional welding.

Figure 5-20

• 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 - -

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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MIG/MAG welding

5.10.7 MIG/MAG functional sequences / operating modes

There are optimum pre-sets for welding parameters such as gas pre-flow and burn back, etc. for numerous applications (although these can also be changed if required).

5.10.7.1 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

Wire electrode is being conveyed

Wire creep

Wire burn-back

Gas pre-flows

Gas post-flows

Non-latched

Special, non-latched

Latched

Special, latched t Time

PSTART Ignition program

PA Main program

PB Reduced main program

PEND End program t2 Spot time

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Non-latched mode


MIG/MAG welding

Figure 5-21

Step 1

• 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 flows.

• Change over to pre-selected wire speed.

Step 2

• Release torch trigger.

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

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MIG/MAG welding

Non-latched operation with superpulse

Figure 5-22

Step 1





• Start the super pulse function beginning with main program P

A

:

The welding parameters change at the specified times between main program P

A

and the reduced main program P

B

.

Step 2


• Super pulse function is ended.

• WF motor stops.



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Special, non-latched


MIG/MAG welding

Figure 5-23

Step 1

• Press and hold torch trigger

• Shielding gas is expelled (gas pre-flows)


• Arc ignites after the wire electrode makes contact with the workpiece, welding current is flowing (start program P

START for the time t start

)

• Slope to main program P

A

.

Step 2

• Release torch trigger

• Slope to end program P

END

for the time t end

.

• WF motor stops.



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MIG/MAG welding

Spot welding

Figure 5-24

The ignition time t start

must be added to the spot time t

2

.

1st cycle



• Wire feed motor runs at "creep speed"


START

, spot time starts)


A

• After the set spot time elapses, slope goes to end program P

END

.

• Wire feed motor stop welding.

• Arc is extinguished after the pre-selected wire burn-back time elapses


2nd cycle


Releasing the torch trigger (step 2) interrupts the welding process even if the spot time has not yet elapsed (slope to end program P

END

).

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Special, non-latched with superpulse


MIG/MAG welding

Figure 5-25

Step 1






).

• Slope on main program P

A

.


A

:


A


B

.

Step 2




END

for the time t end

.

• WF motor stops.



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MIG/MAG welding

Latched mode

Figure 5-26

Step 1





• Change over to pre-selected WF speed (main program P

A

).

Step 2

• Release torch trigger (no effect)

Step 3

• Press torch trigger (no effect)

Step 4


• WF motor stops.



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Latched mode with superpulse


MIG/MAG welding

Figure 5-27

Step 1:






A

.


A


B

.

Step 2:


Step 3:


Step 4:



• WF motor stops.



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MIG/MAG welding

Latched special

58

Figure 5-28

Step 1





START

)

Step 2



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

1)

can be used to change over to the reduced main program P

B

.

Repeated tapping will switch back to the main program P

A

.

Step 3



END

.

Step 4


• WF motor stops.



1)

Prevent tapping (brief press and release within 0.3 seconds)

If the welding current is to be prevented from switching over to the reduced main program P

B

by tapping, the parameter value for WF3 needs to be set to 100% (P

A

= P

B

) in the program sequence.

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Special, latched with superpulse


MIG/MAG welding

Figure 5-29

Step 1






).

Step 2


• Slope on main program P

A

.


A

:


A


B

.

Step 3

• Press the torch trigger.


• Slope in the end program P

END

for the time t end

.

Step 4


• WF motor stops.



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MIG/MAG welding

5.10.8 MIG/MAG program sequence ("Program steps" mode)

Certain materials, such as aluminium, require special functions in order to be able to weld them safely and at high quality. The latched special operating mode is used here with the following programs:

• Start program P

START

(reduction of cool points at the start of the seam)

• Main program P

A

(continuous welding)

• Reduced main program P

B

(targeted heat reduction)

• End program P

END)

(minimisation of end craters via targeted heat reduction)

The programs include the parameters wire speed (operating point), arc length correction, slope times, program duration, etc.

Figure 5-30

This function can only be enabled with the PC300.NET software.

(See operating instructions for the software)

5.10.8.1 Selection of the program sequence parameter

Operating

Element

Action Result

Select parameter in the program sequence n x

Setting welding parameters

Display

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5.10.8.2 MIG/MAG overview of parameters


MIG/MAG welding

Figure 5-31

Basic Parameters

Item Meaning / Explanation Setting Range

1 1

2 2

START

Wire speed, relative

Arc length correction

3 3

4 4

START

to P

A

5 5

A

Wire speed, absolute

6 7

7 8

B

Wire speed, relative

Arc length correction, relative

8 9

9 1

A

to P

END

0

P

END

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

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

2

0.0s to 20s

3

On / Off

4

P

START

, P

B

, and P

END

are set as relative programs ex faxtory. They relate to percentages of the wire feed value of the main program P

A

. These programs can also be set in an absolute manner, if desired (see Setting of special parameter P21).

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MIG/MAG welding

5.10.8.3 Example, tack welding (non-latched)

Figure 5-32

Basic parameters

Parameter Meaning / explanation

GASstr Gas pre-flow time

GASend:

RUECK

Gas post-flow time

Wire burn-back length

"P

A

" main program

Parameter Meaning / explanation

Setting the wire speed

5.10.8.4 Example, aluminium tack welding (non-latched special)

Setting range

0.0s to 20.0s

0.0s to 20s

2 to 500

Setting range

62


Welding parameter Meaning / explanation

GASstr

GASend:

Gas pre-flow time

Gas post-flow time

RUECK Wire burn-back length

"P

START

" start program


DVstart

Ustart

Wire speed

Arc length correction tstart Duration

"P

A

" main program



"P

END

" end-crater program


DVend Wire speed

Uend tend


Duration

Figure 5-33

Setting range

0.0s to 20.0s

0.0s to 20.0s

2 to 500

Setting range

0% to 200%

-9.9V to +9.9V

0.0s to 20s

Setting range

Setting range

0% to 200%

-9.9V to +9.9V

0.0s to 20s

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5.10.8.5 Example, aluminium welding (latched special)


MIG/MAG welding

Figure 5-34



GASstr

GASend:

Gas pre-flow time

Gas post-flow time


"P

START

" start program


DVstart ustart

Wire speed


"P

A

" main program



"P

B

" reduced main program


DV3 Wire speed

U3 Arc length correction

"P

END


Welding parameter Meaning / explanation tSend

DVend

Slope duration from P

Wire speed

A or P

B to P

END

Uend tend


Duration

Setting range

0.0s to 20.0s

0.0s to 20.0s

2 to 500

Setting range

0% to 200%

-9.9V to +9.9V

0.0s to 20s

Setting range

Setting range

0% to 200%

-9.9V to +9.9V

Setting range

0.0s to 20s

0% to 200%

-9.9V to +9.9V

0.0s to 20s

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MIG/MAG welding

5.10.8.6 Example, visible seams (latched super pulse)

64

Figure 5-35



GASstr

GASend:

Gas pre-flow time

Gas post-flow time


"P

START

" start program


DVstart ustart

Wire speed


"P

A

" main program

Welding parameter Meaning / explanation tS1

DV3 t2 tS3


START

to P

A


Duration


B

to P

A

"P

B

" reduced main program

Welding parameter Meaning / explanation tS2 Slope duration from P

A

to P

B

DV3

U3

Wire speed

Arc length correction t3 Duration

"P

END


Welding parameter Meaning / explanation tSend

DVend

Uend tend


Wire speed


Duration

A or P

B to P

END

Setting range

0.0s to 20.0s

0.0s to 20.0s

2 to 500

Setting range

0% to 200%

-9.9V to +9.9V

0.0s to 20s

Setting range

0.0s to 20s

0% to 200%

0.1s to 20s

0.0s to 20s

Setting range

0.0s to 20s

0% to 200%

-9.9V to +9.9V

0.1s to 20s

Setting range

0.0s to 20s

0% to 200%

-9.9V to +9.9V

0.0s to 20s

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MIG/MAG welding

5.10.9 Main program A mode

Different welding tasks or positions on a workpiece demand various welding performances (operating points) or welding programs. The following parameters are stored in each of the up to 16 programs:

• Operating mode

• Welding type

• superPuls (ON/OFF)

• Wire feed speed (DV2)

• Voltage correction (U2)

• Dynamics (DYN2)

The user can change the main program welding parameters using the following components.

M3.7x

Wire feeder control

R20

Remote control

R40

Remote control

R50

Remote control

PC 300.NET

Software

Up/Down

Welding torch

2 Up/Down

Welding torch

PC 1

Welding torch

PC 2

Welding torch

Yes

Yes

Yes

Yes

No

Yes

Yes

Yes

Yes

No

No

No

No

No

No

No

Yes Yes

P0

P1...15

P0

P1...9

P0

P0

P1...15

P0

P1...15

P0

P1...9

P0

P1...15

P0

P1...15

P0

P1...15

No

Yes

No

Yes

Yes

No

No

No

No

Yes

Yes

Yes

Yes

Yes

1)

Yes

No

Yes

No

No

Yes

Yes

Yes

No

Yes

No

Yes

No

No

Yes

No

No

No

No

No

1) in case of correction mode, refer to Special parameters "P7

– correction mode, limit value setting"

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MIG/MAG welding

Example 1: Welding workpieces with different sheet metal thicknesses (non-latched)

Figure 5-36

Example 2: Welding different positions on a workpiece (latched)

Figure 5-37

Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special)

Figure 5-38

Up to 16 programs (P

A0

to P

A15

) can be defined.

An operating point (wire speed, arc length correction, dynamics/choke effect) can be defined permanently in each program.

Program P0 is an exception: the settings for operating points are made manually here.

Changes to the welding parameters are saved immediately!

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5.10.9.1 Selecting parameters (program A)

Changes to the welding parameters can only be made when the key switch is in position "1".


Action Result Display n x

Change welding data display over to program display.

(LED Prog is on)

Select program number.

Display example: Program "1". 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.

1 x

Set dynamic. (Setting range 40 to -40)

40:

-40:

Arc hard and narrow.

Arc soft and wide.

5.10.10 MIG/MAG automatic cut-out

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 intrerrupted for longer than 5 s)

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MIG/MAG welding

5.10.11 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- See 5.17 Special parameters (advanced settings) chapter:

• Change over between welding programs (P8).

• Program selection before starting welding (P17).

• Switching between wire feed units in dual operation mode (P10).

5.10.12 MIG/MAG special-torches

Function specifications and more indepth information can be found in the operating manual for the relevant welding torch!

5.10.12.1 Program- and Up- / down operation

Figure 5-39


1 Welding torch function changeover switch (special welding torch required)

Changing over programs or JOBs

Infinite adjustment of welding performance.

5.10.12.2 Switching between Push/Pull and intermediate drive

DANGER





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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5.10.13 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.

5.10.13.1 Selection

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

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Figure 5-40

69


MIG/MAG welding


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.

For machine versions with pulsed arc welding procedures only.

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 Function activated. off 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 off

Function activated.

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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5.11 TIG welding

5.11.1 Welding torch and workpiece line connection


TIG welding

Figure 5-41


1 Welding torch

2

3

4

Welding torch hose package



Welding current cable, polarity selection

Welding current to the central connector/torch, enables polarity selection.

• TIG: Connection socket for “-” welding current

5

6


•

TIG welding: Workpiece connection

Workpiece

• Insert the central plug for the welding torch into the central connector and screw together with crown nut.

• Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by turning to the right.

• Welding current lead, insert polarity selection into the "-" welding current connection socket and lock.

If fitted:

• 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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TIG welding


• Select JOB 127 (TIG welding task).

It is only possible to change the JOB number when no welding current is flowing.



Select JOB number input

1 x

Set the JOB number

The machine adopts the required setting after approx. 3 seconds

5.11.3 Welding current setting

The welding current is normally set using the "Wire speed" rotary dial.


Action Result

Welding current is set

Displays

Setpoint setting

5.11.4 TIG arc ignition

5.11.4.1 Liftarc ignition

Figure 5-42

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.

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5.11.5 Function sequences/operating modes

5.11.5.1 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


TIG welding

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TIG welding

Non-latched mode

Figure 5-43

Selection

• Select non-latched operating mode

.

Step 1



The arc is ignited using liftarc.

• Welding current flows with pre-selected setting.

Step 2


• Arc is extinguished.


Special, non-latched

74

Figure 5-44

Selection

• Select non-latched special mode .

Step 1




• 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


• 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.


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Latched mode

Figure 5-45

Selection

• Select latched operating mode

.

Step 1




• Welding current flows with pre-selected setting.

Step 2


Step 3


Step 4





TIG welding

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TIG welding

Latched special

Figure 5-46

Selection

• Select latched special mode

.

Step 1




• Welding gas flows at pre-selected setting in start program "P

START

".

Step 2


• Slope on main program "P

A

".

The slope on main program P

A


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




5.11.5.2 TIG automatic cut-out

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 intrerrupted for longer than 5 s)

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5.11.6 TIG program sequence ("Program steps" mode)


TIG welding

Figure 5-47


Item Meaning/explanation

1

2

3

4

Gas pre-flow time

P

START

Ignition current

Duration (start program)

5

6

7


START

to P

A

P

A

(main program)

Welding current, absolute

Duration (P

A

)

P

B

(reduced main program)

Welding current

Setting range

0 s to 0.9 s

0% to 200%

0 s to 20 s

0 s to 20 s

5 A to 550 A

8

9

Duration (reduced main program)


A to P

END

0.01 s to 20.0 s

1% to 100%

0.01 s to 20.0 s

0 s to 20 s

10 P

END

(end program)

Welding current

Duration (end program)

1% to 100%

0 s to 20 s 11

12

13

Gas post-flow time superPuls

0 s to 20 s on/off

P

START

, P

B

, and P

END

are relative programs whose welding current settings are a percentage based on the general welding current setting.

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MMA welding

5.12 MMA welding

CAUTION

Risk of being crushed or burnt.

When replacing spent or new stick electrodes

• Switch off machine at the main switch

• Wear appropriate safety gloves

• Use insulated tongs to remove spent stick electrodes or to move welded workpieces and

• Always put the electrode holder down on an insulated surface.

5.12.1 Connecting the electrode holder and workpiece lead

78

Figure 5-48


1 Workpiece

2

3


• MMA welding: Workpiece connection


• MMA welding: electrode holder connection

4 Park socket, polarity selection plug

Retainer for the polarity selection plug in MMA mode or for transport.

5 Electrode holder

• Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right.

• Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and lock by turning to the right.

• Insert the polarity selection plug in the park socket and lock in place by turning to the right.

Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

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• Select JOB 128 (MMA welding task).

It is only possible to change the JOB number when no welding current is flowing.



Select JOB number input

1 x

MMA welding

Set the JOB number

The machine adopts the required setting after approx. 3 seconds

5.12.3 Welding current setting

The welding current is normally set using the "Wire speed" rotary dial.


Action Result

Welding current is set

Displays

Setpoint setting

5.12.4 Arcforce


Display Action Result

Select arcforcing welding parameter

LED for the button is on.

Arcforcing setting for electrode types:

(Setting range -40 to 40)

Negative values Rutile

Values around zero Basic

Positive values Cellulose

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MMA welding

5.12.5 Hotstart

The hotstart device improves the ignition of the stick electrodes using an increased ignition current. a) = b) =

I = t =

Hotstart time

Hotstart current

Welding current

Time

Figure 5-49

For hotstart parameter settings, - See 5.12.7 Parameter overview chapter

5.12.6 Antistick

Anti-stick prevents the electrode from annealing.

If the electrode sticks in spite of the Arcforce device, the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overheating. Check the welding current setting and correct according to the welding task!

Figure 5-50

5.12.7 Parameter overview

Figure 5-51


Item Meaning/explanation

1 Welding current

2

3

Hotstart time

Hotstart current

Setting range

5 A to maximum welding current

0 to 20 s

0 to 200 %

The hotstart current is a percentage based on the welding current selected.

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Remote control

5.13 Remote control

CAUTION





The remote controls are operated on the 19-pole remote control connection socket (analogue).

Please note the relevant documentation of the accessory components.

5.14 Interfaces for automation

DANGER





CAUTION

Damage due to incorrect connection!

Accessory components and the power source itself can be damaged by incorrect connection!


• 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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Interfaces for automation

5.14.1 Remote control connection socket, 19-pole

Pin

A

C

D

E

F/S

G

P

R

U/V

Figure 5-52

Signal form Short description

Output

Output

Input

Output

Connection for PE cable screen

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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PC Interfaces

5.15 PC Interfaces

CAUTION

Equipment damage or faults may occur if the PC is connected incorrectly!

Not using the SECINT X10USB interface results in equipment damage or faults in signal transmission. The PC may be destroyed due to high frequency ignition pulses.

• Interface SECINT X10USB must be connected between the PC and the welding machine!

• The connection must only be made using the cables supplied (do not use any additional extension cables)!

PC 300 welding parameter software

Create all welding parameters quickly on the PC and easily transfer them to one or more welding machines (accessories: set consisting of software, interface, connection leads).

Q-DOC 9000 welding data documentation software

(Accessories: set consisting of software, interface, connection leads)

The ideal tool for welding data documentation of, for example: welding voltage and current, wire speed and motor current.

WELDQAS welding data monitoring and documentation system

Network-compatible welding data monitoring and documentation system for digital machines

5.16 Protecting welding parameters from unauthorised access

The key switch is only available for machines which are fitted with the "OW KL XX5" option ex works.

To protect against unauthorised or unintentional adjustment of the welding parameters on the machine, the control input can be locked with the aid of a key switch.

In key switch position 1 all functions and parameters can be set without restriction.

In key switch position 0 the following functions and parameters cannot be changed:

• No adjustment of the operating point (welding performance) in programs 1–15.

• No change of welding or operating mode in programs 1–15.

• The welding parameters can be displayed but not changed in the control's function sequence.

• No welding task switching (JOB block operation P16 possible).

• No change of special parameters (except P10). Restart required.

5.17 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- See 5.17.1.1 Reset to factory settings chapter.

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Special parameters (advanced settings)

5.17.1 Selecting, changing and saving parameters


• 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.


• 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.


• Press the "right parameter selection" button (switch machine off and on again).

ENTER

0 l

AMP

+

EXIT

VOLT

Prog kW

Hold

NAVIGATION

84

Figure 5-53

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Display

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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

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

85




Program selection with standard torch trigger

0 = no program selection (Ex works)

1 = program selection possible

Mean value display for superPuls

0 = Function switched off.

1 = Function switched on (ex factory).

Predefined pulse arc welding process in the PA program

0 = Predefined pulse arc welding process in the PA program is disabled.

1 = If the superPuls and welding process switching functions are available and activated, the pulse arc welding process is always executed in the main program PA (ex factory).

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

5.17.1.1 Reset to factory settings

All special parameters saved by the user will be overwritten by the factory settings!


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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5.17.1.2 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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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 5-54

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 5.17.1 Selecting, changing and saving parameters chapter

• Key switch to position "1".

• Set correction range according to the following table:

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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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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 5-55

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

).

90

Figure 5-56

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The number of programs (P

An

) corresponds to the cycle number specified under N cycle.

1st cycle



• Wire feed motor runs at "creep speed".


START from P

A1

)

2nd cycle



A1

.

The slope to main program P

A1


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



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


• WF motor stops.

• Arc is extinguished after the pre-selected wire burn-back 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.

"Single or dual operation" (P10) setting

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 5.16 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.

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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.

2 Actual JOB list,

JOB changeover active

JOB numbers correspond to the actual memory cells. Each JOB can be selected; no memory cells are skipped during selection.

As for the actual JOB list. JOB changeover is also possible with accessory components, such as the PowerControl 2 torch.

Creating user-defined JOB lists

A consecutive memory range where accessories such as the POWERCONTROL 2 torch can be used to switch between JOBs will be created.

• Set special parameter P12 to "2".

• Set "Program or Up/Down function" changeover switch to "Up/Down" position.

• Select an existing JOB which is closest to the required result.

• Copy JOB to one or more target JOB numbers.

If any JOB parameters need to be changed, select the target JOBs in sequence and change the parameters individually.

• Set special parameter P13 to the lower limit and

• Set special parameter P14 to the upper limit of the target JOBs.

• Set "Program or Up/Down function" changeover switch to "Program" position.

JOBs can be changed over in the specified range using the accessory component.

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Copying JOBs, "Copy to" function

The possible target range is between 129 - 169.

• First configure special parameter P12 to P12 = 2 or P12 = 1!


Action Result

Select JOB list

1 x

Display

Select the source JOB

- - Wait for around 3 seconds until the JOB has been transferred

Keep button pressed for around 5s

1 x

Setting to copy function ("Copy to")

Select JOB number of the target JOB

1 x

Save

The JOB is copied to the new position

By repeating the last two steps, the same source JOB can be copied to multiple target JOBs.

If the control does not register any user activity for longer than 5 seconds, the parameter display is shown once more and the copy process is complete.

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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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"

• 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.

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

0

129

1

141

2

142

3

143

4

144

5

145

6

146

7

147

8

148

9

149

Special JOB 2

Special JOB 3

JOB 0:

130 151 152 153 154 155 156 157 158 159

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).

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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Machine configuration menu

Mean value display for superPuls (P19)

Function active (P19 = 1)

• For superPuls, the performance mean value from program A (P

A

) and program B (P

B

) is shown on the display (ex factory).

Function inactive (P19 = 0)

• Only the performance of program A is displayed for superPuls.

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)



• If the superPuls and welding process switching functions are available and activated, the pulse arc welding process is always executed in the main program PA (ex factory).


• Predefined execution of the pulse 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.


• Absolute parameter setting


• Relative parameter setting (ex factory)

5.18 Machine configuration menu

5.18.1 Selecting, changing and saving parameters


• Switch off the machine at the main switch.

• Press and hold the "welding parameters" or "choke effect" (drive 4X LP) push-button and switch the machine on again at the same time.


• 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.


• Press the "parameter selection right" push-button (switch machine off and on again).

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ENTER

0 l

+

+

EXIT

VOLT

Prog kW

0 l

NAVIGATION

Display

Figure 5-57


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

Service menu

Modifications to the service menu may only be carried out by authorised maintenance staff!

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5.18.2 Adjusting 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-adjusting 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/min

3

B

A

4

0 l

Figure 5-58

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1 Preparation

• Switch off the welding machine.

• Unscrew the gas nozzle from the welding torch.

• Trim the welding wire, so that it is flush with the contact tip.

• Retract the welding wire a little (approx. 50 mm) on the wire feeder. There should now be no more welding wire in the contact tip.

2 Configuration

• Press the "welding parameter or choke effect" push-button while simultaneously switching on the welding machine. Release push-button.

•

•

"Welding parameter" push-button on the M3.7x-A and M3.7x-C control.

"Choke effect" push-button on the M3.7x-B and M3.7x-D control.

• The required parameter can now be selected using the 'Welding parameter setting' rotary knob.

Parameter rL1 must be adjusted for all machine combinations. In case of welding systems with a second power circuit – if two wire feeders are to be operated from a single power source, for example

– a second adjustment with parameter rL2 must be performed.

3 Adjustment/measurement

• Applying slight pressure, put the welding torch in place with the contact tip on a clean, purged location on the workpiece and then press the torch trigger for approx. 2 seconds. A short-circuit current will flow briefly, which is used to determine and display the cable resistance. The value can be between

0 mΩ and 40 mΩ. The new value is immediately saved without requiring further confirmation. If no value is shown on the right-hand display, then measurement failed. The measurement must be repeated.

4 Restoring welding standby mode

• Switch off the welding machine.

• Screw the gas nozzle onto the welding torch.

• Switch on the welding machine

• Insert the welding wire.

5.18.3 Power-saving mode (Standby)

The power-saving function can be activated either by pressing the button for a longer time - See 4.3

Machine control

– Operating elements chapter or by setting a parameter in the configuration menu (timebased 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!

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.

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

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 work, intervals

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)

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 more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com

!

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.

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Disposing of equipment

6.3 Disposing of equipment

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!

6.3.1 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.

6.4 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 2011/65/EU).

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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

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

Wire feed problems

 Contact tip blocked

 Clean, spray with anti-spatter spray and replace if necessary

 Setting the spool brake - See 5.10.2.5 Spool brake setting chapter

 

Check settings and correct if necessary

 Setting pressure units - See 5.10.2.4 Inching the wire electrode 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 5.16 Protecting welding parameters from unauthorised access chapter

 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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Error messages

7.2 Error messages

7.3 Error messages (power source)

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 Possible cause a) b) c)

- - x Mains overvoltage

Remedy

Error 1

(Ov.Vol)

Error 2

(Un.Vol)

Error 3

(Temp)

Error 4

(Water)

- - x Mains undervoltage x - - Welding machine excess temperature x x - Low coolant level

Check the mains voltages and compare with the connection voltages of the welding machine

Error 5

(Wi.Spe)

Error 6

(gas)

Error 7

(Se.Vol)

Error 8

(no PE)

Error 9

(fast stop) x - - Wire feeder/speedometer error x - - Shielding gas error

- - x 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,

M3.51 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

Rectify error on robot

Error 10

(no arc)

Error 11

(no ign)

Error 14

(no DV)

Error 15

(DV2?)

Error 16

(VRD)

Error 18

(Wf.Sl.)

- - x Earth fault between welding wire and earth line x - - Fast cut-out triggered by BUSINT X11 or

RINT X12

- 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 - - Auxiliary drive/ speedometer error

Check wire feeding

Check wire feeding

Check cable connection

Check assignment of ID numbers

Check cable connection

Inform Service

Check auxiliary drive tachogenerator not issuing signals.

M3.51 defective > inform Service

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Error messages (power source)

Error

Error 17

(WF. Ov.)

Error 18

(WF. Sl.)

Error 56

(no Pha)

Category Possible cause a) b) c)

- x x Wire feed mechanism overcurrent detection

- x x No speedometer signal from second wire feeder (slave drive)

- - x Mains phase failure

Remedy

Check the wire feeding

Check the connection and particularly the speedometer of the second wire feeder

(slave drive).

Check mains voltages

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

RC1 / RC2

Expert

CarExpert / Progress (M3.11) not possible alpha Q / Concept / Basic / Basic S / Synergic /

Synergic S / Progress (M3.71) / Picomig 305 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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Resetting JOBs (welding tasks) to the factory settings

7.4 Resetting JOBs (welding tasks) to the factory settings

All customised welding parameters that are stored will be replaced by the factory settings.

7.4.1 Resetting a single JOB

ENTER RESET

3 s

3 s

EXIT

3 s

Display

Figure 7-1


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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Resetting JOBs (welding tasks) to the factory settings

7.4.2 Resetting all JOBs

JOBs 1

–128 and 170–256 will be reset.

Custom JOBs 129 –169 are maintained.

ENTER

3 s

RESET

3 s

EXIT

3 s

Display

Figure 7-2


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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Technical data

Taurus 355 Synergic S

8 Technical data

8.1 Taurus 355 Synergic S

Performance specifications and guarantee only in connection with original spare and replacement parts!

MIG/MAG

Setting range Welding current

Setting range Welding voltage 14,3 V - 31,5 V

Duty cycle at 25 °C ambient temperature

45% DC

60% DC

100% DC

Duty cycle at 40 °C ambient temperature

40% DC

60% DC

100% DC

Load alternation

Open circuit voltage

Mains voltage (tolerances)

MMA

5 A-350 A

20,2 V - 34,0 V

350 A

320 A

290 A

350 A

300 A

TIG

10,2 V - 24,0 V

270 A

10 min. (60% DC



6 min. welding, 4 min. pause)

79 V

3 x 400 V (-25% to +20%)

50/60 Hz

3 x 16 A

Frequency

Mains fuse

(safety fuse, slow-blow)

Mains connection lead

Maximum connected load

Recommended generator rating

Cos



/ Efficiency

Insulation class/protection classification

Ambient temperature

Machine cooling

Workpiece lead

Dimensions L/W/H [mm]

Weight

Wire feed speed

Factory-fit roller equipment

Drive

EMC class

Constructed to standards

13.9 kVA

H07RN-F4G2.5

15.0 kVA

20,3 kVA

0.99% / 88%

H/IP 23

-25



C to +40



C

Fan

50 mm

2

636 x 297 x 482

36 kg

0.5 m/min to 24 m/min

1.0 mm + 1.2 mm (for steel wire)

4-roller (37 mm)

A

IEC 60974-1, -5, -10

/

10.6 kVA

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Accessories

General accessories

9 Accessories

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

Trolly 55-5 cool50 U40

TYP 1

KF 23E-10

KF 23E-200

KF 37E-10

KF 37E-200

AK300

Transport cart, assembled

Cooling module

Frost protection tester

Coolant (-10 °C), 9.3 l

Coolant (-10 °C), 200 litres

Coolant (-20 °C), 9.3 l

Coolant (-20 °C), 200 l

Wire spool adapter K300

DMDIN TN 200B AR/MIX 35L Manometer pressure regulator

GH 2X1/4'' 2M Gas hose

5POLE/CEE/32A/M Machine plug

9.2 Remote control/connecting and extension cable

9.2.1 7-pole connection


R40 7POL

R50 7POL

FRV 7POL 0.5 m

FRV 7POL 5 m

FRV 7POL 10 m

FRV 7POL 20 m

FRV 7POL 25M

9.2.2 19-pole connection

Type

R10 19POL

RG10 19POL 5M

Remote control, 10 programs

Remote control, all welding machine functions can be set directly at the workplace

Extension/connecting cable





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



Extension cable

Extension cable

Extension cable

Extension cable

Item no.

090-008632-00000

090-008598-00502

094-014499-00000

094-000530-00000

094-000530-00001

094-006256-00000

094-006256-00001

094-001803-00001

094-000009-00000

094-000010-00001

094-000207-00000

Item no.

090-008088-00000

090-008776-00000

092-000201-00004

092-000201-00003

092-000201-00000

092-000201-00001

092-000201-00007

Item no.

090-008087-00000

090-008108-00000

090-008263-00000

092-001470-00005

092-001470-00010

092-001470-00020

092-000857-00000

092-000857-00010

092-000857-00015

092-000857-00020

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Accessories

Options

9.3 Options

Type

ON D BARREL

ON MF XX5

ON CS 55

Designation

Wire guide Rolliner for drum feed

Dirt filter

Crane suspension, retrofit option

Item no.

092-007929-00000

092-002662-00000

092-002549-00000

9.4 Computer communication

Type

PC300.Net

FRV 7POL 5 m

FRV 7POL 10 m

FRV 7POL 20 m

QDOC9000 V2.0

Designation

PC300.Net welding parameter software kit incl. cable and SECINT X10 USB interface



Item no.

090-008777-00000

092-000201-00003

092-000201-00000


Set consisting of interface, documentation software, connection lead

092-000201-00001

090-008713-00000

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Replaceable parts

Wire feed rollers

10 Replaceable parts

CAUTION





10.1 Wire feed rollers

10.1.1 Wire feed rollers for steel wire

Type Designation Item no.

092-002770-00008 FE 4R 0.8 MM/0.03 INCH

WHITE

FE 4R 1,0 MM/0.04 INCH

BLUE

FE 4R 1.2 MM/0.045 INCH

RED

FE 4R 1.4 MM/0.052 INCH

GREEN

FE 4R 1.6 MM/0.06 INCH

BLACK


GREY

FE 4R 2.4 MM/0.095 INCH

BROWN


LIGHT GREEN


VIOLET

Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing









092-002770-00010

092-002770-00012

092-002770-00014

092-002770-00016

092-002770-00020

092-002770-00024

092-002770-00028

092-002770-00032

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Replaceable parts

Wire feed rollers

10.1.2 Wire feed rollers for aluminium wire


AL 4R 0.8 MM/0.03 INCH

WHITE

Drive roll set, 37 mm, for aluminium

Drive roll set, 37 mm, for aluminium AL 4R 1.0 MM/0.04 INCH

BLUE

AL 4R 1.2 MM/0.045 INCH

RED


BLACK


GREY/YELLOW

AL 4R 2.4 MM/0.095 INCH

BROWN/YELLOW

AL 4R 2.8 MM/0.110 INCH

LIGHT GREEN/YELLOW

AL 4R 3.2 MM/0.125 INCH

VIOLET/YELLOW







Item no.

092-002771-00008

092-002771-00010

092-002771-00012

092-002771-00016

092-002771-00020

092-002771-00024

092-002771-00028

092-002771-00032

10.1.3 Wire feed rollers for cored wire


FUEL 4R 0.8 MM/0.03 INCH

WHITE/ORANGE

Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire


BLUE/ORANGE


RED/ORANGE


GREEN/ORANGE


BLACK/ORANGE


GREY/ORANGE


BROWN/ORANGE







10.1.4 Wire guide

Type

SET DRAHTFUERUNG

ON WF 2,0-3,2MM EFEED

SET IG 4x4 1.6mm BL

GUIDE TUBE L105

CAPTUB L108 D1,6

CAPTUB L108 D2,0/2,4

Item no.

092-002848-00008

092-002848-00010

092-002848-00012

092-002848-00014

092-002848-00016

092-002848-00020

092-002848-00024

Designation Item no.

Wire guide set

Retrofitting option, wire guide for 2.0

–3.2 mm wires, eFeed drive

092-002774-00000

092-019404-00000

Inlet guide set

Guide tube

Capillary tube

Capillary tube

092-002780-00000

094-006051-00000

094-006634-00000

094-006635-00000

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Appendix A

JOB-List

11 Appendix A

11.1 JOB-List

112

Figure 11-1

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12 Appendix B

12.1 Overview of EWM branches

Appendix B

Overview of EWM branches

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