099 005442 EW501
Operating instructions
Welding machine
Taurus 355 Basic TKW
099-005442-EW501 23.04.2015
Register now
and benefit!
Jetzt Registrieren
und Profitieren!
www.ewm-group.com
*
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
Open the protective flap of the wire feeder ................................................... 39
Accessory components for operating point setting ....................................... 45
099-005442-EW501
23.04.2015
3
Contents
Notes on the use of these operating instructions
4
099-005442-EW501
23.04.2015
Contents
Notes on the use of these operating instructions
099-005442-EW501
23.04.2015
5
Safety instructions
Notes on the use of these operating instructions
2
Safety instructions
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general warning symbol.
• The risk is explained using a symbol on the edge of the page.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general warning symbol.
• The hazard is explained using a symbol at the edge of the page.
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.
6
099-005442-EW501
23.04.2015
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)
Safety instructions
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
099-005442-EW501
23.04.2015
7
Safety instructions
General
2.3 General
DANGER
Electromagnetic fields!
The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers.
• Observe the maintenance instructions - See 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!
8
099-005442-EW501
23.04.2015
Safety instructions
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!
099-005442-EW501
23.04.2015
9
Safety instructions
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.
10
099-005442-EW501
23.04.2015
Safety instructions
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
099-005442-EW501
23.04.2015
11
Safety instructions
Transport and installation
2.4
Transport and installation
WARNING
Incorrect handling of shielding gas cylinders!
Incorrect handling of shielding gas cylinders can result in serious and even fatal injury.
• Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air!
• Place shielding gas cylinders in the holders provided for them and secure with fixing devices.
• Avoid heating the shielding gas cylinder!
Risk of accident due to improper transport of machines that may not be lifted!
Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only!
• The machine may not be lifted by crane or suspended!
CAUTION
Risk of tipping!
There is a risk of the machine tipping over and injuring persons or being damaged itself during movement and set up. Tilt resistance is guaranteed up to an angle of 10°
(according to IEC 60974-1).
• Set up and transport the machine on level, solid ground.
• Secure add-on parts using suitable equipment.
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads, control leads, etc.) may cause hazards such as connected equipment tipping over and injuring persons!
• Disconnect supply lines!
CAUTION
Equipment damage when not operated in an upright position!
The units are designed for operation in an upright position!
Operation in non-permissible positions can cause equipment damage.
• Only transport and operate in an upright position!
12
099-005442-EW501
23.04.2015
Safety instructions
Transport and installation
2.4.1
Ambient conditions
CAUTION
Installation site!
The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base!
• The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work.
• Safe operation of the machine must be guaranteed at all times.
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
• Avoid ambient air containing salt (sea air)!
Non-permissible ambient conditions!
Insufficient ventilation results in a reduction in performance and equipment damage.
• Observe the ambient conditions!
• Keep the cooling air inlet and outlet clear!
• Observe the minimum distance of 0.5 m from obstacles!
2.4.1.1 In operation
Temperature range of the ambient air:
• -25 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
2.4.1.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -30 °C to +70 °C
Relative air humidity
• Up to 90% at 20 °C
099-005442-EW501
23.04.2015
13
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 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
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 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.
14
099-005442-EW501
23.04.2015
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
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.
3.2.5 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
099-005442-EW501
23.04.2015
15
Machine description
– quick overview
Front view
4
Machine description – quick overview
4.1 Front view
16
Figure 4-1
099-005442-EW501
23.04.2015
Machine description
– quick overview
Front view
Item Symbol Description 0
1
2
Protective cap
- See 5.3.1 Protective flap, welding machine control chapter
Machine control- See 4.3 Machine control
3
4
5
6
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
Welding torch connection (Euro or Dinse torch connector)
Welding current, shielding gas and torch trigger integrated
Slide latch, lock for the protective cap
7
8
9
10
11
Park socket, polarity selection plug
Retainer for the polarity selection plug in MMA mode or for transport.
Quick connect coupling, red
Coolant return from the welding torch
Quick connect coupling, blue
Coolant supply to the welding torch
Cooling air inlet
Coolant tank
12
Coolant tank cap
13
14
15
16
Welding current cable, polarity selection
Welding current to the central connector/torch, enables polarity selection.
• MIG/MAG: Connection socket for “+” welding current
• Self-shielding cored wire
Connection socket, “-” welding current
• MIG/MAG welding: workpiece connection
• MIG/MAG cored wire welding:
• MMA welding: welding current connection for the welding torch electrode holder connection
Connection socket, “+” welding current
• MIG/MAG welding: welding current connection for the welding torch
• MIG/MAG cored wire welding:
• MMA welding: workpiece connection workpiece connection
19-pole connection socket (analogue)
For connecting analogue accessory components (remote control, welding torch control lead, etc.)
099-005442-EW501
23.04.2015
17
Machine description
– quick overview
Rear view
4.2 Rear view
18
Figure 4-2
099-005442-EW501
23.04.2015
Machine description
– quick overview
Rear view
4
5
6
7
Item Symbol Description 0
1
2
Transport bar
Main switch, machine on/off
3
Connecting nipple G¼, shielding gas connection
8
9
10
Cooling air inlet
Cooling air outlet
Machine feet
Automatic cut-out of coolant pump key button
press to reset a triggered fuse
Mains connection cable
- See 5.6 Mains connection chapter
External wire feed inlet
Pre-cut casing inlet for external wire feed.
Carrying handle
099-005442-EW501
23.04.2015
19
Machine description
– quick overview
Rear view
4.2.1 Operating elements in the machine
20
Figure 4-3
099-005442-EW501
23.04.2015
Machine description
– quick overview
Rear view
Item Symbol Description 0
1
2
Key button, automatic cutout
Wire feed motor supply voltage fuse press to reset a triggered fuse
D-sub connection socket, 9-pole
With this machine series for maintenance purposes only (specialist staff)
3
Wire spool holder
4
Wire feed unit
099-005442-EW501
23.04.2015
21
Machine description
– quick overview
Machine control
– Operating elements
4.3 Machine control
– Operating elements
22
Figure 4-4
099-005442-EW501
23.04.2015
Machine description
– quick overview
Machine control
– Operating elements
Item Symbol Description 0
1
Button, welding process
MIG/MAG welding
MMA welding
Air arc gouging
2
3
4
5
6
7
Display, left
Welding current, wire feed speed
Status displays
"Welding current display" signal light
"Wire feed speed display" signal light
Display, welding process
J1 MIG/MAG welding
J2
J3
MMA welding
Gouging
Welding parameter setting, rotary dial
For setting the welding performance, for selecting the JOB (welding task) and for setting other welding parameters.
Select operating mode button
Non-latched
Latched
Push-button, throttling effect (arc dynamics)
8
9
10
11
12
Arc is harder and more narrow
Arc is softer and wider
Rotary dial, welding voltage
Adjustment of the welding voltage from min. to max.
(twin-knob operation: wire speed/welding voltage)
Button, Parameter selection (right)
VOLT Welding voltage kW Welding performance display
Gas flow quantity (optional)
Display, right
Welding voltage, welding performance, motor current (wire feed mechanism) during wire inching, shielding gas flow rate (option)
Gas test / rinse button
• Gas test:
• Rinse:
For setting the shielding gas quantity
For rinsing longer hose packages
- See 5.7 Shielding gas supply (shielding gas cylinder for welding machine) chapter
Push-button, wire inching/motor current (wire feed mechanism)
- See 5.9.2.4 Inching the wire electrode chapter
099-005442-EW501
23.04.2015
23
Design and function
Machine control
– Operating elements
5
Design and function
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.
24
099-005442-EW501
23.04.2015
Design and function
Machine cooling
CAUTION
Damage due to incorrect connection!
Accessory components and the power source itself can be damaged by incorrect connection!
• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.
• Comprehensive descriptions can be found in the operating instructions for the relevant accessory components.
• Accessory components are detected automatically after the power source is switched on.
Using protective dust caps!
Protective dust caps protect the connection sockets and therefore the machine against dirt and damage.
• The protective dust cap must be fitted if there is no accessory component being operated on that connection.
• The cap must be replaced if faulty or if lost!
5.1
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.
5.2 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!
099-005442-EW501
23.04.2015
25
Design and function
Installation
5.3
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!
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.
5.3.1 Protective flap, welding machine control
Figure 5-1
Item Symbol Description 0
1
Protective cap
2
3
Lid
Bracket, protective cap
• Push the right-hand bracket of the protective cap to the right and remove the protective cap.
26
099-005442-EW501
23.04.2015
Design and function
Notes on the installation of welding current leads
5.4 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).
099-005442-EW501
23.04.2015
Figure 5-2
27
Design and function
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
28
099-005442-EW501
23.04.2015
Design and function
Welding torch cooling system
5.5 Welding torch cooling system
CAUTION
Coolant mixtures!
Mixtures with other liquids or the use of unsuitable coolants result in material damage and renders the manufacturer's warranty void!
• Only use the coolant described in this manual (overview of coolants).
• Do not mix different coolants.
• When changing the coolant, the entire volume of liquid must be changed.
Insufficient frost protection in the welding torch coolant!
Depending on the ambient conditions, different liquids are used for cooling the welding
torch - See 5.5.1 List of coolants chapter.
Coolants with frost protection (KF 37E or KF 23E) must be checked regularly to ensure that the frost protection is adequate to prevent damage to the machine or the accessory components.
• The coolant must be checked for adequate frost protection with the TYP 1 frost protection tester .
• Replace coolant as necessary if frost protection is inadequate!
The disposal of coolant must be carried out according to official regulations and observing the relevant safety data sheets (German waste code number: 70104)!
Coolant must not be disposed of together with household waste.
Coolant must not be discharged into the sewerage system.
Recommended cleaning agent: water, if necessary with cleaning agent added.
5.5.1 List of coolants
The following coolants may be used - See 9 Accessories chapter:
Coolant Temperature range
KF 23E (Standard) -10 °C to +40 °C
KF 37E -20 °C to +10 °C
5.5.2 Maximal hose package length
Pump 3.5 bar Pump 4.5 bar
Machines with or without separate wire feeder
Compact machines with additional intermediate drive (example. miniDrive)
30 m
20 m
60 m
30 m
Machines with separate wire feeder and additional intermediate drive (example: miniDrive)
20 m 60 m
Data as a rule refer to the entire hose package length including welding torch. The pump output is shown on the type plate (parameter: Pmax).
Pump 3.5 bar: Pmax = 0.35 MPa (3.5 bar)
Pump 4.5 bar: Pmax = 0.45 MPa (4.5 bar)
099-005442-EW501
23.04.2015
29
Design and function
Welding torch cooling system
5.5.3 Adding coolant
The unit is supplied ex works with a minimum level of coolant.
Figure 5-5
Item Symbol Description 0
1
Coolant tank cap
2
Coolant filter sieve
3
Coolant tank
4
"Min" mark
Minimum coolant level
• Unscrew and remove the coolant tank sealing cover.
• Check filter sieve insert for dirt, clean if necessary and reinsert into position.
• Top up coolant to the filter sieve insert, close sealing cover again.
After the initial filling, wait for at least one minute when the machine is switched on so that the hose package is filled with coolant completely and without bubbles.
With frequent changes of torch and during the initial filling process, the cooling unit tank should be topped up as necessary.
The level of coolant must never fall below the “min” mark.
If there is less coolant in the coolant tank than the minimum required you may need to vent the coolant circuit. In this case the welding machine will automatically shut down the coolant pump
and signal an error, "- See 7 Rectifying faults chapter".
30
099-005442-EW501
23.04.2015
Design and function
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 5-6
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.
099-005442-EW501
23.04.2015
31
Design and function
Shielding gas supply (shielding gas cylinder for welding machine)
5.7 Shielding gas supply (shielding gas cylinder for welding machine)
5.7.1 Connecting the shielding gas supply
WARNING
Risk of injury due to improper handling of shielding gas cylinders!
Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries!
• The fastening elements must tightly enclose the shielding gas cylinder!
• Attach the fastening elements within the upper half of the shielding gas cylinder!
• Do not attach any element to the shielding gas cylinder valve!
• Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air!
• Avoid heating the shielding gas cylinder!
• When using shielding gas cylinders smaller than 50 litres, the ON
HOLDER GAS BOTTLE option must be retrofitted
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.
32
099-005442-EW501
23.04.2015
Design and function
Shielding gas supply (shielding gas cylinder for welding machine)
• Place the shielding gas cylinder into the relevant cylinder bracket.
• Secure the shielding gas cylinder using a securing chain.
Figure 5-7
Item Symbol Description 0
1
Pressure regulator
2
Shielding gas cylinder
3
Output side of the pressure regulator
4
Cylinder valve
• Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight.
• Screw gas hose connection crown nut onto the output side of the pressure regulator.
• Fasten the gas hose to the shielding gas connecting nipple at the back of the machine using the crown nut.
5.7.2 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.
5.7.3 Adjusting the gas post-flow time
ENTER EXIT
3 s
3 s
Figure 5-8
099-005442-EW501
23.04.2015
33
Design and function
Shielding gas supply (shielding gas cylinder for welding machine)
5.7.4 Setting the shielding gas quantity
Welding process Recommended shielding gas quantity
MAG welding
MIG brazing
Wire diameter x 11.5 = l/min
Wire diameter x 11.5 = l/min
MIG welding (aluminium) Wire diameter x 13.5 = l/min (100 % argon)
Helium-rich gas mixtures require a higher gas volume!
The table below can be used to correct the gas volume calculated where necessary:
Shielding gas
75% Ar/25% He
50% Ar/50% He
25% Ar/75% He
100% He
Factor
1.14
1.35
1.75
3.16
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!
34
099-005442-EW501
23.04.2015
Design and function
Welding data display
5.8 Welding data display
Figure 5-9
The machine control displays show all welding parameters that are required by the welder. The lower centre display shows the selected welding task (JOB number). The "parameter selection" ( ) pushbutton can be used to switch the display between welding voltage, welding performance and gas flow rate
(option).
What is shown on the displays depends, among other things, on the selected welding procedure and the machine state (welding, power-saving mode, machine error).
MIG/MAG welding
Parameter
Welding current
Nominal values
Actual values
Hold values
Wire feed speed
Welding voltage
Welding performance
MMA welding
Parameter
Welding current
Welding voltage
Welding performance
Nominal values
Actual values
Hold values
099-005442-EW501
23.04.2015
35
Design and function
MIG/MAG welding
5.9 MIG/MAG welding
5.9.1 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.
Preparation for connecting welding torches with a spiral guide:
• Check that the capillary tube is correctly positioned in relation to the central connector!
36
099-005442-EW501
23.04.2015
Design and function
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 5-10
Item Symbol Description 0
1
Welding torch
2
3
4
5
6
7
8
9
Welding torch hose package
Welding torch connection (Euro or Dinse torch connector)
Welding current, shielding gas and torch trigger integrated
19-pole connection socket (analogue)
Connection for welding torch control lead
Quick connect coupling (red)
coolant return
Quick connect coupling (blue)
coolant supply
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
"-" welding current connection socket
•
MIG/MAG welding: Workpiece connection
Workpiece
099-005442-EW501
23.04.2015
37
Design and function
MIG/MAG welding
• 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.
• 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).
Where applicable:
• Insert the welding torch control cable into the 19-pole connection socket and lock (MIG/MAG torches with additional control cables only).
38
099-005442-EW501
23.04.2015
Design and function
MIG/MAG welding
5.9.2 Wire feed
5.9.2.1 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.
5.9.2.2 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 5-11
Item Symbol Description 0
1
2
Carrier pin
For fixing the wire spool
Knurled nut
For fixing the wire spool
• Loosen knurled nut from spool holder.
• Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore.
• Fasten wire spool using knurled nut.
099-005442-EW501
23.04.2015
39
Design and function
MIG/MAG welding
5.9.2.3 Changing the wire feed rollers
Figure 5-12
Item Symbol Description 0
1
2
Tommy
The tommy is used to secure the closure brackets of the wire feed rollers.
Closure bracket
The closure brackets are used to secure the wire feed rollers.
3
4
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.
40
099-005442-EW501
23.04.2015
Design and function
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
Flux cored wire
0.8
0.9
1.0
1.2
1.4
1.6
2.0
2.4
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
3.2
.030
.035/.040
045
052
060
.080
.095
.110
.125
.030
.035/.040
.045
.060
.080
.095
.110
.125
.030
.035
.040
.045
.052
.060
.080
.095 monochrome bichrome bichrome white blue red black grey brown
Light green purple white blue white blue red green black grey brown
Light green purple red green black grey brown
- yellow orange
V-groove
U-groove
V-groove, knurled
- See 10 Replaceable parts chapter
099-005442-EW501
23.04.2015
41
Design and function
MIG/MAG welding
5.9.2.4 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.
42
099-005442-EW501
23.04.2015
Design and function
MIG/MAG welding
Figure 5-13
Item Symbol Description 0
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 .
• The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll tensioner setting nuts depending on the welding consumable used. A table with the setting values can be found on a sticker near the wire drive.
Version 1: left hand mounting Version 2: right hand mounting
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.
099-005442-EW501
23.04.2015
43
Design and function
MIG/MAG welding
5.9.2.5 Spool brake setting
Figure 5-14
Item Symbol Description 0
1
Allen screw
Securing the wire spool retainer and adjustment of the spool brake
• Tighten the Allen screw (8 mm) in the clockwise direction to increase the braking effect.
Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation!
44
099-005442-EW501
23.04.2015
5.9.3 Welding task selection
Design and function
MIG/MAG welding
Figure 5-15
5.9.3.1 Accessory components for operating point setting
The operating point setting can also be made with the accessory components
• R11 / RG11 remote control
• Up/Down torch with two rockers (2 U/D)
You will find an overview of accessory components in the "Accessories" chapter. See the operating instructions for the machine in question for a more detailed description of the individual machines and their functions.
099-005442-EW501
23.04.2015
45
Design and function
MIG/MAG welding
5.9.4 MIG/MAG functional sequences / operating modes
5.9.4.1 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
Latched
t
Time
PSTART Ignition program
PA
Main program
PEND
End program
46
099-005442-EW501
23.04.2015
Design and function
MIG/MAG welding
Non-latched mode
Figure 5-16
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.
099-005442-EW501
23.04.2015
47
Design and function
MIG/MAG welding
Latched mode
Figure 5-17
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 WF speed (main program P
A
).
Step 2
• Release torch trigger (no effect)
Step 3
• Press torch trigger (no effect)
Step 4
• Release torch trigger
• WF motor stops.
• Arc is extinguished after the preselected wire burn-back time expires.
• Gas post-flow time elapses.
48
099-005442-EW501
23.04.2015
Design and function
MIG/MAG welding
5.9.5 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
5.9.6 MIG/MAG special-torches
Function specifications and more indepth information can be found in the operating manual for the relevant welding torch!
099-005442-EW501
23.04.2015
49
Design and function
MMA welding
5.10 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.
5.10.1 Connecting the electrode holder and workpiece lead
50
Figure 5-18
Item Symbol Description 0
1
Workpiece
2
3
Connection socket, "+" welding current
• MMA welding:
Workpiece connection
"-" welding current connection socket
• 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.
099-005442-EW501
23.04.2015
5.10.2 Welding task selection
Design and function
MMA welding
Figure 5-19
5.10.2.1 Welding current setting
The welding current is normally set using the "Wire speed" rotary dial.
Operating element
Action Result
Welding current is set
Displays
Setpoint setting
5.10.2.2 Arcforce
Operating element
Action Result Display
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
5.10.2.3 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 5-20
5.10.2.4 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 5-21
099-005442-EW501
23.04.2015
51
Design and function
Air arc gouging
5.11 Air arc gouging
5.11.1 Connection
Please note the relevant documentation of the accessory components.
Special electrode holders and carbon electrodes are required for air arc gouging.
Figure 5-22
Item Symbol Description 0
1
Gouging torch
2
3
4
Connection socket, “+” welding current
Workpiece
Connection socket,
“-” welding current
• Insert the gouging torch cable plug into the "+" welding current connection socket and lock in place by turning to the right.
• Insert cable plug on the workpiece lead into the "-" welding current socket and lock by turning to the right.
Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.
52
099-005442-EW501
23.04.2015
Design and function
Air arc gouging
5.11.2 Welding task selection
Figure 5-23
5.11.2.1 Welding current setting
The welding current is normally set using the "Wire speed" rotary dial.
Operating element
Action Result
Welding current is set
Displays
Setpoint setting
099-005442-EW501
23.04.2015
53
Design and function
Remote control
5.12 Remote control
CAUTION
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.
The remote controls are operated on the 19-pole remote control connection socket (analogue).
Please note the relevant documentation of the accessory components.
5.13 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).
5.13.1 Selecting, changing and saving parameters
ENTER (Enter the menu)
• Switch off the machine at the main switch.
• Press and hold the "operating mode" push-button and switch the machine on again at the same time.
NAVIGATION (Navigate the menu)
• Select parameters by turning the "welding parameter setting" rotary knob.
• Set or change the parameters by turning the "welding voltage" rotary knob.
EXIT (Exit the menu)
• Press the "gas test" push-button (switch machine off and on again).
54
099-005442-EW501
23.04.2015
ENTER
0 l
+
Design and function
Special parameters (advanced settings)
EXIT
Display
Figure 5-24
Setting/selection
Ramp time for wire inching
0 = normal inching (10s ramp time)
1 = fast inching (3s ramp time) (Ex works)
Lat. and sp. lat. tapping start
0 = no latched tapping start (Ex works)
1 = latched tapping start possible
Support for wire feeders with voltage-sensing.
0 = Function switched off
1 = Function switched on (ex works)
Alternative remote control coding (FRC)
0 = no alternative remote control coding (works setting)
1-15 = alternative remote control coding
099-005442-EW501
23.04.2015
55
Design and function
Special parameters (advanced settings)
5.13.1.1 Reset to factory settings
All special parameters saved by the user will be overwritten by the factory settings!
Operating element
Action Result left
Display right
Switch off welding machine
Press and hold push-button
Switch on welding machine
Release push-button
Wait for about 3 s
Switch off the welding machine and restart in order to implement the changes.
5.13.1.2 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.
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.
56
099-005442-EW501
23.04.2015
Design and function
Machine configuration menu
5.14 Machine configuration menu
5.14.1 Selecting, changing and saving parameters
ENTER (Enter the menu)
• Switch off the machine at the main switch.
• Press and hold the "welding procedure" push-button and switch the machine on again at the same time.
NAVIGATION (Navigate the menu)
• Select parameters by turning the "welding parameter setting" rotary knob.
• Set or change the parameters by turning the "welding voltage" rotary knob.
EXIT (Exit the menu)
• Press the "gas test" push-button (switch machine off and on again).
ENTER EXIT
0 0 l
+
l
NAVIGATION
Figure 5-25
Display Setting/selection
Lead resistance 1
Lead resistance for the first welding circuit 0 mΩ–60 mΩ (8 mΩ ex works).
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
5.14.2 Power-saving mode (Standby)
The power-saving function can be activated either by pressing the button for a longer time - See 4.3
– Operating elements chapter or by setting a parameter in the configuration menu (time-
based power-saving mode).
When power-saving mode is activated, both machine displays show the horizontal digit in the centre of the display only.
Pressing any operating element (e.g. tapping the torch trigger) deactivates power-saving mode and the machine is ready for welding again.
099-005442-EW501
23.04.2015
57
Maintenance, care and disposal
General
6
Maintenance, care and disposal
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
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)
58
099-005442-EW501
23.04.2015
Maintenance, care and disposal
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.
099-005442-EW501
23.04.2015
59
Maintenance, care and disposal
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).
60
099-005442-EW501
23.04.2015
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
Coolant error/no coolant flowing
Insufficient coolant flow
Check coolant level and refill if necessary
Air in the coolant circuit
Vent coolant circuit
Wire feed problems
Contact tip blocked
Clean, spray with anti-spatter spray and replace if necessary
Setting the spool brake - See 5.9.2.5 Spool brake setting chapter
Check settings and correct if necessary
Setting pressure units - See 5.9.2.4 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)
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
099-005442-EW501
23.04.2015
61
Rectifying faults
Error messages (power source)
7.2 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 a) b) c)
Possible cause
- - 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.)
Error 17
(WF. Ov.)
- - 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
- x x Wire feed mechanism overcurrent detection
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
Check the wire feeding
62
099-005442-EW501
23.04.2015
Rectifying faults
Error messages (power source)
Error
Error 18
(WF. Sl.)
Category a) b) c)
Possible cause
- x x No speedometer signal from second wire feeder (slave drive)
- - x Mains phase failure
Remedy
Check the connection and particularly the speedometer of the second wire feeder
(slave drive).
Check mains voltages Error 56
(no Pha)
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 Key button
RC1 / RC2
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.
099-005442-EW501
23.04.2015
63
Rectifying faults
Welding parameter calibration
7.3 Welding parameter calibration
When differentiating between the welding parameters set on the wire feed unit/remote control and those shown on the welding machine, they can be calibrated easily with this function.
ENTER NAVIGATION EXIT
0 l
+
3,5
4
3
2,5
2
1,5
1
0,5
5
6
7 8 9 10
11
12
13
14
15
24
22
16
18
20 m/min
3,5
4
3
2,5
2
1,5
1
0,5
5
6
7 8 9 10
11
12
13
14
15
24
22
16
18
20 m/min
3,5
4
3
2,5
2
1,5
1
0,5
5
6
7 8 9 10
11
12
13
14
15
24
22
16
18
20 m/min
3,5
4
3
2,5
2
1,5
1
0,5
5
6
7 8 9 10
11
12
13
14
15
22
24
16
18
20 m/min
20
25
15
10
30
35
40
50
45
20
25
15
10
30
35
40
50
45
Figure 7-1
20
25
15
10
30
35
40
50
45
20
25
15
10
30
35
40
50
45
64
099-005442-EW501
23.04.2015
Rectifying faults
Vent coolant circuit
7.4 Vent coolant circuit
To vent the cooling system always use the blue coolant connection, which is located as deep as possible inside the system (close to the coolant tank)!
099-005442-EW501
23.04.2015
Figure 7-2
65
Rectifying faults
Fixing the pump shaft (coolant circuit)
7.5 Fixing the pump shaft (coolant circuit)
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
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!
Continuing non-use and impurities in the coolant may result in the the coolant pump not being in proper working order.
Figure 7-3
• Switch off machine at the main switch.
• Insert a plain slot screwdriver with a maximum tip width of 6.5 mm through the maintenance opening and place in the centre of the pump shaft. Turn the screwdriver clockwise until the pump shaft can be easily rotated again.
• Remove screwdriver.
• Switch on the power source at the main switch.
66
099-005442-EW501
23.04.2015
Technical data
Fixing the pump shaft (coolant circuit)
8
Technical data
Performance specifications and guarantee only in connection with original spare and replacement parts!
Setting range for welding current
Setting range for welding voltage
Duty cycle at 25 °C ambient temperature
45% DC
60% DC
100% DC
Duty cycle at 40 °C ambient temperature
65% DC
60% DC
100% DC
Wire spool diameter
Load cycle
Open circuit voltage
Mains voltage (tolerances)
Frequency
Mains fuse
(safety fuse, slow-blow)
Mains connection lead
Max. connected load
Recommended generator rating cos
/efficiency
Insulation class/protection classification
Ambient temperature*
Machine/welding torch cooling
Cooling capacity at 1 l/min
Maximum flow rate
Maximum coolant outlet pressure
Tank capacity
Workpiece lead
Dimensions (L x W x H)
Weight
EMC class
Constructed to standard
MIG/MAG
14.3 V
–31.5 V
5 A
–350 A
350 A
320 A
290 A
MMA
20.2 V
–34.0 V
350 A
300 A
270 A
Standardized wire spools up to 300 mm
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
14.3 kVA
H07RN-F4G2,5
20.8 kVA
0.99/88%
H/IP 23
15.4 kVA
-25
C to +40
C
Fan/water
1000 W
5 l/min
3.5 bar
5 l
50 mm
2
625 mm x 300 mm x 810 mm
49 kg
A
IEC 60974-1, -2, -5, -10
/
*Ambient temperature depends on coolant! Observe the coolant temperature range for the welding torch cooling!
099-005442-EW501
23.04.2015
67
Accessories
General accessories
9
Accessories
9.1
General accessories
Type Designation
Trolly 55-5
TYP 1
Transport cart, assembled
Frost protection tester
KF 23E-10
KF 23E-200
KF 37E-10
KF 37E-200
Coolant (-10 °C), 9.3 l
Coolant (-10 °C), 200 litres
Coolant (-20 °C), 9.3 l
Coolant (-20 °C), 200 l
AK300 Wire spool adapter K300
DMDIN TN 200B AR/MIX 35L Manometer pressure regulator
GH 2X1/4'' 2M
5POLE/CEE/16A/M
Gas hose
Machine plug
SPL
HC PL
Sharpener for plastic liners
Hose cutter
9.2
Remote control / connection cable
Type Designation
R11 19POL
RG11 19POL 5M
RA5 19POL 5M
RA10 19POL 10M
Remote control
Remote control
Remote control e.g. connection cable
Remote control e.g. connection cable
RA20 19POL 20M
9.3 Options
Type
ON MF XX5
Remote control e.g. connection cable
Designation
Dirt filter
Item no.
090-008632-00000
094-014499-00000
094-000530-00000
094-000530-00001
094-006256-00000
094-006256-00001
094-001803-00001
094-000009-00000
094-000010-00001
094-000712-00000
094-010427-00000
094-016585-00000
Item no.
090-008601-00502
090-008107-00000
092-001470-00005
092-001470-00010
092-001470-00020
Item no.
092-002662-00000
68
099-005442-EW501
23.04.2015
Replaceable parts
Wire feed rollers
10
Replaceable parts
CAUTION
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products!
• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.
10.1 Wire feed rollers
10.1.1 Wire feed rollers for steel wire
Type Designation
FE 4R 0.6 MM/0.023 INCH
LIGHT PINK
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
FE 4R 2.0 MM/0.08 INCH
GREY
FE 4R 2.4 MM/0.095 INCH
BROWN
Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing
Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing
Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing
Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing
Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing
Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing
Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing
Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing
Item no.
092-002770-00006
092-002770-00008
092-002770-00010
092-002770-00012
092-002770-00014
092-002770-00016
092-002770-00020
092-002770-00024
FE 4R 2.8 MM/0.11 INCH
LIGHT GREEN
FE 4R 3.2 MM/0.12 INCH
VIOLET
Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing
Drive roll set, 37 mm, 4 rolls, V-groove for steel, stainless steel and brazing
092-002770-00028
092-002770-00032
099-005442-EW501
23.04.2015
69
Replaceable parts
Wire guide
10.1.2 Wire feed rollers for aluminium wire
Type Designation
Drive roll set, 37 mm, for aluminium AL 4R 0.8 MM/0.03 INCH
WHITE
AL 4R 1.0 MM/0.04 INCH
BLUE
Drive roll set, 37 mm, for aluminium
AL 4R 1.2 MM/0.045 INCH
RED
AL 4R 1.6 MM/0.06 INCH
BLACK
AL 4R 2.0 MM/0.08 INCH
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
Drive roll set, 37 mm, for aluminium
Drive roll set, 37 mm, for aluminium
Drive roll set, 37 mm, for aluminium
Drive roll set, 37 mm, for aluminium
Drive roll set, 37 mm, for aluminium
Drive roll set, 37 mm, for aluminium
10.1.3 Wire feed rollers for cored wire
Type Designation
FUEL 4R 0.8 MM/0.03 INCH
WHITE/ORANGE
FUEL 4R 1.0 MM/0.04 INCH
BLUE/ORANGE
FUEL 4R 1.2 MM/0.045 INCH
RED/ORANGE
FUEL 4R 1.4 MM/0.052 INCH
GREEN/ORANGE
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire
FUEL 4R 1.6 MM/0.06 INCH
BLACK/ORANGE
FUEL 4R 2.0 MM/0.08 INCH
GREY/ORANGE
FUEL 4R 2.4 MM/0.095 INCH
BROWN/ORANGE
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire
Drive roll set, 37 mm, 4 rolls, V-groove/knurled for flux cored wire
10.2 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.
092-002771-00008
092-002771-00010
092-002771-00012
092-002771-00016
092-002771-00020
092-002771-00024
092-002771-00028
092-002771-00032
Item no.
092-002848-00008
092-002848-00010
092-002848-00012
092-002848-00014
092-002848-00016
092-002848-00020
092-002848-00024
Designation
Wire guide set
Retrofitting option, wire guide for 2.0
–3.2 mm wires, eFeed drive
Item no.
092-002774-00000
092-019404-00000
Inlet guide set
Guide tube
092-002780-00000
094-006051-00000
Capillary tube
Capillary tube
094-006634-00000
094-006635-00000
70
099-005442-EW501
23.04.2015
11
Appendix A
11.1 Setting instructions
Appendix A
Setting instructions
099-005442-EW501
23.04.2015
Figure 11-1
71
Appendix B
Overview of EWM branches
12
Appendix B
12.1 Overview of EWM branches
72
099-005442-EW501
23.04.2015
* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project