EWM drive 4 Basic MMA Operating Instructions Manual Download Page 1

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Operating instructions

Wire feed unit

drive 4 Basic
drive 4 Basic MMA

099-005401-EW501

Observe additional system documents!

17.06.2014

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Summary of Contents for drive 4 Basic MMA

Page 1: ...ed unit drive 4 Basic drive 4 Basic MMA 099 005401 EW501 Observe additional system documents 17 06 2014 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Details for e...

Page 2: ...ment 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 monit...

Page 3: ...view 18 4 4 Machine control Operating elements 19 5 Design and function 20 5 1 General 20 5 2 Installation 21 5 3 Welding torch cooling system 22 5 3 1 List of coolants 22 5 4 Notes on the installatio...

Page 4: ...6 4 Disposing of equipment 45 6 4 1 Manufacturer s declaration to the end user 45 6 5 Meeting the requirements of RoHS 45 7 Rectifying faults 46 7 1 Checklist for rectifying faults 46 7 2 Error messag...

Page 5: ...l 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...

Page 6: ...ess Do not press Turn Switch Switch off machine Switch on machine ENTER ENTER ENTER enter the menu NAVIGATION NAVIGATION Navigating in the menu EXIT EXIT Exit the menu 4 s Time display example wait 4s...

Page 7: ...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...

Page 8: ...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 workp...

Page 9: ...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 sec...

Page 10: ...he 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...

Page 11: ...itable 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 d...

Page 12: ...ties 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 ambie...

Page 13: ...AG 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 2 MMA welding Manual arc...

Page 14: ...7 06 2014 3 2 Use and operation solely with the following machines NOTE A suitable power source system component is required in order to operate the wire feed unit Taurus 351 401 451 551 Basic Basic d...

Page 15: ...d with the unit 3 3 3 Welding in environments with increased electrical hazards In compliance with IEC DIN EN 60974 VDE 0544 the machines can be used in environments with an increased electrical hazar...

Page 16: ...chanism 5 Welding torch connection Euro or Dinse torch connector Welding current shielding gas and torch trigger integrated 6 Machine feet 7 Welding current connection socket ex works option Welding c...

Page 17: ...eeder 2 G connecting nipple shielding gas connection 3 19 pole connection socket analogue Wire feed unit control lead connection 4 Protective cap 5 Turning mandrel support The wire feeder is placed on...

Page 18: ...n is held 6 Push button wire inching For inching the wire electrode after changing wire spools The welding wire is inched through the hose package to the welding torch without any voltage or gas 7 Cha...

Page 19: ...er switch Switching between non latched and latched operating modes Non latched operation Latched operation 3 Rotary dial welding voltage Adjustment of the welding voltage from min to max 4 Changeover...

Page 20: ...ction 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 di...

Page 21: ...erated on that connection The cap must be replaced if faulty or if lost NOTE Observe documentation of other system components when connecting 5 2 Installation WARNING Risk of accident due to improper...

Page 22: ...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 protect...

Page 23: ...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 p...

Page 24: ...7 06 2014 NOTE Use an individual welding lead to the workpiece for each welding machine Figure 5 2 NOTE Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loop...

Page 25: ...nnect coupling blue coolant supply Insert the hose package end through the intermediate hose package strain relief and secure with the safety belt as shown in the figure Push the welding current cable...

Page 26: ...key The shielding gas will flow as long as you keep the button pressed 5 6 2 Setting the shielding gas quantity Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11 5 l m...

Page 27: ...es with spiral guides Conversion is necessary if a welding torch with a plastic core is used Welding torch with plastic core use with guide tube Welding torch with spiral guide use with capillary tube...

Page 28: ...plastic core guide tube off the central connector Carefully insert the central plug for the welding torch with the still oversized plastic liner into the central connector and screw together with crow...

Page 29: ...socket analogue For connecting analogue accessory components remote control welding torch control lead etc Insert the central plug for the welding torch into the central connector and screw together w...

Page 30: ...y 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...

Page 31: ...xing the clamping unit and setting the pressure 4 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 Fol...

Page 32: ...llers are colour coded to facilitate distinction see the Wire feed roller overview table Wire feed roller overview table Material Diameter Colour code Groove form mm inch Steel Stainless steel Flux co...

Page 33: ...tervals 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...

Page 34: ...and automatically guides it to the welding torch outlet NOTE A prerequisite for the automatic inching process is the correct preparation of the wire guide especially in the capillary and wire guide t...

Page 35: ...Description 0 1 Allen screw Securing the wire spool retainer and adjustment of the spool brake Tighten the Allen screw 8 mm in the clockwise direction to increase the braking effect NOTE Tighten the s...

Page 36: ...parameters can be set on the wire feed unit 1 4 15 50 10 20 25 35 40 45 30 2 3 1 5 Figure 5 12 5 7 3 1 Accessory components for operating point setting The operating point setting can also be made wit...

Page 37: ...e MIG welding torch trigger is essentially used to start and stop the welding process Operating elements Functions Torch trigger Start stop welding 5 7 5 MIG MAG special torches Function specification...

Page 38: ...he relevant documentation of the accessory components 5 8 1 Connecting the electrode holder and workpiece lead Figure 5 13 Item Symbol Description 0 1 Intermediate hose package 2 Electrode holder 3 We...

Page 39: ...de types Setting range 40 to 40 Negative values Rutile Values around zero Basic Positive values Cellulose 5 8 5 Hotstart The hotstart device improves the ignition of the stick electrodes using an incr...

Page 40: ...tion Figure 5 17 Item Symbol Description 0 1 Intermediate hose package 2 Gouging torch 3 Welding current connection socket ex works option Welding current potential of the torch connector for MMA weld...

Page 41: ...01 EW501 17 06 2014 41 5 9 2 Welding task selection Figure 5 18 5 9 3 Welding current setting The welding current is normally set using the Wire speed rotary dial Operating element Action Result Displ...

Page 42: ...ine is switched off NOTE The remote controls are operated on the 19 pole remote control connection socket analogue Please note the relevant documentation of the accessory components The operation of t...

Page 43: ...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 leng...

Page 44: ...lding power sources as well as possible subsequent damage and who is able to implement the required safety procedures For further information please see the accompanying supplementary sheets Machine a...

Page 45: ...ded 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...

Page 46: ...ol brake see Setting the spool brake chapter Check settings and correct if necessary Setting pressure units see Inching wire electrodes chapter Check settings and correct if necessary Worn wire rolls...

Page 47: ...ire feeder speedometer error Check the wire feeder speedometer is not issuing a signal M3 00 defective inform Service Error 6 gas x Shielding gas error Check shielding gas supply for machines with shi...

Page 48: ...end 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...

Page 49: ...ed easily with this function ENTER 0 5 1 1 5 2 2 5 3 3 5 4 5 6 7 8 9 10 11 12 13 14 15 16 18 20 22 24 m min 0 5 1 1 5 2 2 5 3 3 5 4 5 6 7 8 9 10 11 12 13 14 15 16 18 20 22 24 m min 0 5 1 1 5 2 2 5 3 3...

Page 50: ...circuit NOTE Coolant tank and quick connect coupling of coolant supply and return are only fitted in machines with water cooling To vent the cooling system always use the blue coolant connection which...

Page 51: ...50 A Maximum welding current at 100 DC 430 A Wire feed speed 0 5 m min 24 m min 19 68 ipm 944 88 ipm Factory installed roller equipment 1 2 mm for steel wire Drive 4 roll 37 mm Wire spool diameter Sta...

Page 52: ...n 090 008108 00000 R20 19POL Program changeover remote control 090 008263 00000 RA5 19POL 5M Remote control e g connection cable 092 001470 00005 RA10 19POL 10M Remote control e g connection cable 092...

Page 53: ...omes 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 p...

Page 54: ...7 mm universal 092 002770 00016 10 1 1 2 Wire feed rollers for aluminium wire Type Designation Item no AL 4R 0 8 MM 0 03 INCH WHITE Drive roll set 37 mm for aluminium 092 002771 00008 AL 4R 1 0 MM 0 0...

Page 55: ...Appendix A Setting instructions 099 005401 EW501 17 06 2014 55 11 Appendix A 11 1 Setting instructions Figure 11 1...

Page 56: ...Appendix B Overview of EWM branches 56 099 005401 EW501 17 06 2014 12 Appendix B 12 1 Overview of EWM branches...

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EWM drive 4 Basic MMA, Operating Instructions Manual

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