EWM T5.00 Operating Instructions Manual Download Page 1

Page: 1 / 81

Operating instructions

Control

T5.00 - AC/DC Comfort 3.0

099-00T500-EW501 Observe additional system documents!

2.9.2022

Summary of Contents for T5.00

Page 1: ...Operating instructions EN Control T5 00 AC DC Comfort 3 0 099 00T500 EW501 Observe additional system documents 2 9 2022...

Page 2: ...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 ac...

Page 3: ...er setting in theoperationsequence 22 4 3 4 Setting advanced welding parameters Expert menu 23 4 3 5 Changing basic settings machineconfiguration menu 23 4 3 6 Lock function 23 5 Functional characteri...

Page 4: ...matic AC frequency 56 5 3 7 Pulse welding 57 5 3 7 1 Averagevaluepulse welding 57 5 4 Arc length restriction USP 57 5 5 JOB favourites 58 5 5 1 Saving current settings to Favourites 58 5 5 2 Loading s...

Page 5: ...Contents Notes on using these operating instructions 099 00T500 EW501 2 9 2022 5 8 2 Searching for adealer 81...

Page 6: ...and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning sym bol The hazard is also highlighted using a symbol in the page margin CAUTION Working or oper...

Page 7: ...on machine Press and hold Incorrect Invalid Switch Correct Valid Turn Input Numerical value adjustable Navigation Signal light lights up in green Output Signal light flashes green Time representation...

Page 8: ...cal specialist may interconnect the sources as per standard IEC 60974 9 2010 Installa tion and use and German Accident Prevention Regulation BVG D1 formerly VBG 15 or country specific regulations Befo...

Page 9: ...emperatures of 100 C or higher and arcing and work on live components Hearing protection against harming noise Explosion risk Apparently harmless substances in closed containers may generate excessive...

Page 10: ...ified 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...

Page 11: ...lacement parts etc from our range of products Only insert and lock accessory components into the relevant connection socket when the ma chine is switched off Requirements for connection to the public...

Page 12: ...or connection points can heat up significantly during operation water cooled version When opening the coolant circuit escaping coolant may cause scalding Open the coolant circuit only when the power...

Page 13: ...plate 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...

Page 14: ...this marking can be used for welding in an environment with increased electrical hazard e g boilers For this purpose appropriate national or international regulations must be followed The power sourc...

Page 15: ...combination with all other parts of these instructions Read and observe the operating instructions for all system components especially the safety instructions The illustration shows a general example...

Page 16: ...escription purposes the machine control has been divided into three sections A B C to ensure maximum clarity The setting range for the parameter values are summarised in the parameter overview section...

Page 17: ...ion protection against accidental adjustment see 4 3 6chapter 2 push button JOB Favourites see 5 5 chapter Pressing the push button briefly Loading Favourites Press and hold the push button 2 s Saving...

Page 18: ...sing push button see 5 2 8 chapter Average value pulsing Thermal pulsing Automated pulsing AC special 7 Push button for welding current polarity tungsten balling DC welding with either negative or pos...

Page 19: ...millimetres 7 Signal light display value in inch 8 Excess temperature signal light In case of excess temperature temperature monitors de activate the power unit and the excess temperature control lamp...

Page 20: ...is active on the machine con trol see 5 8 chapter 15 Without function in this machine version 16 Signal light welding voltage Illuminates when the welding voltage is displayed in volts 17 Without fun...

Page 21: ...n TIG 7 JOB Signal light for welding task JOB 8 tst Signal light for start current time 9 Signal light activArc see 5 2 6 chapter 10 Signal light for balance 11 t1 Signal light for pulse time 12 Signa...

Page 22: ...ans that the previously selected settings are accepted if necessary indicated by signal lights and the nominal value of the current A is shown in the welding data display on the left The welding data...

Page 23: ...hold the click wheel 2 s Select the appropriate parameter menu item by turning navigating and pressing confirming the click wheel 4 3 5 Changing basic settings machine configuration menu The basic we...

Page 24: ...mm corresponds to the gas flow in l min 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 Factor 75 A...

Page 25: ...eter a minimum current limit is set that in turn affects the start main and secondary currents Minimum current limits prevent an unstable arc at impermissibly low currents If necessary the minimum cur...

Page 26: ...arameters ignition current and ignition time The ignition time is set absolutely in milliseconds The setting of the ignition current differs in the setting variants and In the variant the ignition cur...

Page 27: ...ing task as described previously With the JOB manager see 5 6 chapter welding tasks canbe copied to any preset or reset to thefac tory settings The desired JOB can also be assigned to a quick access b...

Page 28: ...ode Pulse function 1 80A Non latched Pulses on 2 70A latched Pulses off The operating mode cannot be changed during the welding process If welding is started with program 1 non latched operating mode...

Page 29: ...electrode tip melts into a ball the so called balled end due to the high thermal effect of thepositive half wave The size of the balled end depends on the length balance setting see 5 2 3 3 chapter an...

Page 30: ...and thus the balled end size The function is enabled by pressing thepush button tungsten balling and indicated by the flashing of the corresponding signal light If required this current can be adjust...

Page 31: ...setting of the balance is 65 and always refers to the negative half wave The positive half wave is adjusted accordingly negative half wave 65 positive half wave 35 Figure 5 9 5 2 3 4 AC amplitude bal...

Page 32: ...hine control takes over the regulation or setting of the alternating current frequency depending on the set main current The lower the welding current the higher the frequency and vice versa This achi...

Page 33: ...g task Automatic modeis the preferred choice for almost every ap plication Manual mode 1 100 If the result in automatic mode is not satisfactory in rare cases the commutation optimisation can be adjus...

Page 34: ...nding on the operat ing mode set to the ignition or main current set c Lift off the torch and swivel to the normal position Ending the welding process Release the torch trigger or press and release de...

Page 35: ...in current minimum to maximum current AMP Secondary current Pulse time Pulse pause time Pulse current Latched operating mode Slope time from main current AMP to secondary current AMP TIG thermal pulsi...

Page 36: ...the HF ignition shuts down The welding current increases in the up slope time to the main current 2nd cycle Release torch trigger 1 The main current drops during the down slope time to theend current...

Page 37: ...g gas is shut down Alternative welding start tap start The tap start function must be switched on before using it With the alternative welding start the du ration of the first and second cycle is only...

Page 38: ...es jump from the electrode to the workpiece The arc ignites The welding current flows and immediately assumes the value of the start current HF switches off The welding current ramps up to the main cu...

Page 39: ...he torch trigger Process activation is automatically terminated after 30 s of inactivity Permanent process activation The welding process is activated by pressing the torch trigger once The following...

Page 40: ...Press and release the torch trigger tap to reactivate the welding process only for separate process activation Touching the welding torch with the tungsten electrode tip against the workpiece again wi...

Page 41: ...events the tungsten electrodesticking in the molten pool and the tungsten inclusions are reduced Selection 4s Figure 5 23 Setting Parameter setting The activArc parameter control can be adjusted speci...

Page 42: ...lace periodically between two currents whereby an average current value AMP a pulse current Ipuls pulse balance and pulse frequency must be spe cified The set averagecurrent value in ampere is decisiv...

Page 43: ...onds on the control The and pulse edges can be set in the Expert menu TIG see 5 2 12 chapter Figure 5 26 Setting the pulse and pulse pause time 4s Figure 5 27 5 2 9 2 Automated pulses The automated pu...

Page 44: ...al sheets of different thickness Pulse time setting Figure 5 28 The and pulse edges can be set in the Expert menu TIG see 5 2 12 chapter 5 2 9 4 Pulsing in an upslope downslope The pulse function can...

Page 45: ...ase the value DOWN Torch trigger DOWN decrease the value The torch modes are set using the torch configuration parameters in the machine configuration menu torch mode see 5 11 chapter Only the modes l...

Page 46: ...ent in steps current jump UP Decrease welding current in steps current jump DOWN Welding torch with two torch triggers and up down push buttons Figure 5 33 Function Operation Mode Welding current On O...

Page 47: ...ondary current in latched operation Secondary current in latched operation BRT 2 Increase welding current in steps current jump UP Decrease welding current in steps current jump DOWN Switching between...

Page 48: ...separately for each torch mode for the start of welding with parame ter and for the end of welding with parameter If parameter is activated there is no need to tap the secondary current 5 2 10 3 Up do...

Page 49: ...e remote control pe dal very quickly down by approx 50 of the pedal travel Start ramp is switched on The welding current increases in a linear slow ramp to approx 100 A Start ramp is switched off The...

Page 50: ...e between linear and logarithmic responsiveness The logarithmic setting is particularly suitable for welding with low current e g for thin panels as the logarithmic responsiveness enables better contr...

Page 51: ...Slope time main current to secondary current Slope time secondary current to main current Amplitude balance see 5 2 3 4 chapter Commutation optimisation AC see 5 2 3 6 chapter Parameter activArc see 5...

Page 52: ...an accessory component suchas the welding torch or the intermediate hose package AW has been chan ged The resistance value of the cables can beset directly or can be aligned by the power source In the...

Page 53: ...against a clean purged location on the workpiece and then press the torch trigger for approx 2 seconds A short circuit current will flow briefly which is used to determine and display the cable resist...

Page 54: ...he selection process always has the same sequence Signal lights LED will show the selected combination Cel Cel Figure 5 39 5 3 2 Hotstart The function hot start ensures a secure igniting of the arc an...

Page 55: ...trode types at low current strengths with a short arc in particular 4s Arcforce Arcforce Figure 5 42 5 3 4 Antistick The Antistick feature prevents the electrode from annealing Should the electrode st...

Page 56: ...ency By turning to the left the parameter value is reduced until the parameter AC frequency automatic is shown in the display The signal light comes on when the function is enabled The machine control...

Page 57: ...s a percentage of the current average value AMP The pulse pausecurrent IPP requires no setting This value is calculated by the machine control so that the welding current average value AMP is maintain...

Page 58: ...he push button 2 s Saving as a Favourite Press and hold the push button 12 s Deleting a Favourite 2 Signal light of Favourite status Signal light is green Favourite loaded settings of the Favourite an...

Page 59: ...er 2 seconds the signal light of thefavourite status turns green after another 5 s the signal light starts flashing red after another 5 s the signal light goes out Release the favourite memory push bu...

Page 60: ...ntrol can be locked to secure it against unauthorised or unintentional adjustment The access block has the following effect The parameters and their settings in the machine configuration menu Expert m...

Page 61: ...cification This function enables aligning the machine to the mains connection fusing This may counteract frequent tripping of the mains fuse The maximum input power of the machine is limited with an e...

Page 62: ...n factory setting hard ignition Ignition pulse dynamics Function enabled factory setting Function disabled Minimum current limit TIG see 5 1 2 chapter Depending on the set tungsten electrode diameter...

Page 63: ...nction enabled ex works Function disabled Spot time setting see 5 2 5 5 chapter Short spot time setting range 5 ms to 999 ms increments of 1 ms ex works Long spot time setting range 0 01 s to 20 0 s i...

Page 64: ...mps up to the preset main current factory setting The welding current jumps immediately to the preset main current Responsiveness see 5 2 11 2 chapter Linear responsiveness Logarithmic responsiveness...

Page 65: ...ching via interface for automated welding Non latched Special non latched Error output relay 3 Potential free relay contact Relay contact for error message is open factory setting Relay contact for er...

Page 66: ...n accidental selection of polarity DC and the associated destruction of the tungsten electrode factory setting Polarity switching to DC is possible Polarity switching is disabled factory setting Gas m...

Page 67: ...ety precautions Follow the maintenance instructions If any of the test requirements below are not met the unit must not be put back into opera tion until it has been repaired and tested again Repair a...

Page 68: ...em 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 ch...

Page 69: ...coolant level and top up if necessary 4 Shielding gas Check shielding gas supply 5 Coolant flow Check min flow rate 2 6 Wire reserve Only a small amount of wire is left on the spool 7 CAN bus failure...

Page 70: ...rent detected onwire feed motor 34 JOB unknown JOB selection was not carried out because the JOB number is unknown 35 Excess current on the wire feed motor slave Excess current detected onwire feed mo...

Page 71: ...eliminated B The error message can be reset by pressing a push button All other error messages can only be reset by switching the machine off and on again Error 3 Tacho error Category A B Fault in th...

Page 72: ...ng Connect the coolant feed and return with a hose bridge Error 8 Shielding gas error Category A B No shielding gas Check the shielding gas supply The pre pressure is too low Remove kinks in the hose...

Page 73: ...place Air inlet or outlet is blocked Check the air inlet and outlet Short circuit on welding torch Check the welding torch Request service Error 17 Cold wire error Category B Fault in the wire feeder...

Page 74: ...he switched on machine to cool Fan is blocked dirty or defective Check clean or replace the fan Air inlet or outlet is blocked Check the air inlet and outlet Error 23 Excess temperature of the HF chok...

Page 75: ...equest service Error 37 Electronics error The power source is overheating Allow the switched on machine to cool Fan is blocked dirty or defective Check fan and clean or replace Air inlet or outlet is...

Page 76: ...n activated internally configurable Deactivate the emergency stop circuit Error 52 No wire feeder After switching on the automated system no wire feeder DV was detected Check or connect the control ca...

Page 77: ...achine from the system Request service Error 61 Welding monitoring The actual value of a welding parameter is outside thespecified tolerance range Maintain the tolerance ranges Adjust the welding para...

Page 78: ...time 0 01 s 0 01 20 0 Slope time time from to 0 00 s 0 00 20 0 Main current power source dependent A Slope time time from to 0 00 s 0 00 20 0 Slope time time from to 0 00 s 0 00 20 0 Secondary curren...

Page 79: ...e value pulsing DC 2 00 Hz 0 10 20000 Pulse frequency average value pulsing AC 2 00 Hz 0 10 5 00 8 1 1 2 AC parameters Name Display Setting range Code Standard Unit min max Balance 65 40 90 Frequency...

Page 80: ...00 Balance 60 40 90 8 1 3 Global parameters Name Display Setting range Code Standard Unit min max Standby 20 m 5 60 Re ignite after arc interruption Job s 0 1 5 Torch mode 1 1 6 Up down speed 10 1 100...

Page 81: ...Appendix Searching for a dealer 099 00T500 EW501 2 9 2022 81 8 2 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldwide...

Search results

Summary of Contents for T5.00

Reviews:

Related manuals for T5.00

Brands by name

Popular brands

EWM T5.00, Operating Instructions Manual

Search results

Summary of Contents for T5.00

Reviews:

Related manuals for T5.00

Brands by name

Popular brands