EWM TIGSPEED OSCILLATION DRIVE 45 COLDWIRE Operating Instructions Manual Download Page 1

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Operating instructions

Wire feed unit

tigSpeed continuous drive 45 coldwire

099-000237-EW501

Observe additional system documents!

25.04.2019

Summary of Contents for TIGSPEED OSCILLATION DRIVE 45 COLDWIRE

Page 1: ...Operating instructions EN Wire feed unit tigSpeed continuous drive 45 coldwire 099 000237 EW501 Observe additional system documents 25 04 2019 ...

Page 2: ... authorised sales partners can be found at www ewm group com en specialist dealers 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 ac cepted by the user on commissioning the equipment The manufacturer is unable to monitor whether or...

Page 3: ...1 In operation 27 5 1 2 2 Transport and storage 27 5 1 3 Machine cooling 27 5 1 4 Workpiece lead general 27 5 1 5 Notes on the installation of welding current leads 28 5 1 6 Stray welding currents 29 5 1 7 Mains connection 30 5 1 7 1 Mains configuration 30 5 1 8 Welding torch cooling system 30 5 1 8 1 Permitted torch coolant 31 5 1 8 2 Maximal hose package length 31 5 1 9 Intermediate hose package...

Page 4: ...d testing during operation 54 6 3 Disposing of equipment 55 7 Rectifying faults 56 7 1 Checklist for rectifying faults 56 7 2 Error messages 57 7 3 Resetting welding parameters to the factory settings 58 7 4 Vent coolant circuit 59 8 Technical data 60 8 1 tigSpeed continuous drive 45 coldwire 60 9 Accessories 61 9 1 Options 61 9 2 General accessories 61 10 Replaceable parts 62 10 1 Wire feed rolle...

Page 5: ...Contents Notes on the use of these operating instructions 099 000237 EW501 25 04 2019 5 ...

Page 6: ...serious 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 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 warn ing symbol The r...

Page 7: ...itch off machine Release Switch on machine Press and hold Switch Incorrect Invalid Turn Correct Valid Numerical value adjustable Input Signal light lights up in green Navigation Signal light flashes green Output Signal light lights up in red Time representation e g wait 4 s actuate Signal light flashes red Interruption in the menu display other setting options possible Tool not required do not use...

Page 8: ...on and valid only in 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 of a welding system Figure 2 1 Item Operating instructions A 1 Wire feeder A 2 Power source A 3 Remote control A 4 Control A 5 Welding torch A Complete documentation ...

Page 9: ...hen taking individual power sources out of operation all mains and welding current leads must be safely disconnected from the welding system as a whole Hazard due to reverse polarity voltage Do not interconnect welding machines with pole reversing switch PWS series or machines for AC welding since a minor error in operation can cause the welding voltages to be com bined which is not permitted Risk...

Page 10: ... fire extinguishers are available in the working area Thoroughly remove any residue of flammable materials from the workpiece prior to starting to weld Only further process workpieces after they have cooled down Do not allow them to contact any flammable materials CAUTION Smoke and gases Smoke and gases can lead to breathing difficulties and poisoning In addition solvent vapour chlorinated hydroca...

Page 11: ...ied out Recommendations for reducing interference emission Mains connection e g additional mains filter or shielding with a metal tube Maintenance of the arc welding system 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...

Page 12: ...ements 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 th...

Page 13: ...pack ages can present a tripping hazard Lay the supply lines flat on the floor avoid loops Avoid laying the leads on passage ways Risk of injury from heated coolant and its connections The coolant used and its connection 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 ...

Page 14: ...s 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 its designated purpose and by trained or expert personnel Do not improperly modify or convert the equipment 3 1 Use and operation solely with the following machines A suitable power source system component is require...

Page 15: ...horised by the manufacturer this declaration shall be voided An original document of the specific declaration of conformity is included with every product 3 3 3 Service documents spare parts and circuit diagrams WARNING 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 warrant...

Page 16: ...Machine description quick overview Front view 16 099 000237 EW501 25 04 2019 4 Machine description quick overview 4 1 Front view Figure 4 1 ...

Page 17: ... supply 5 Slide latch lock for the protective cap 6 Machine feet 7 Torch holder 8 Protective cap see 5 1 1 chapter 9 Key switch for protection against unauthorised use see 5 3 chapter 1 changes possible G front drive 4x EX 0 changes not possible 10 Machine control see 4 3 chapter 11 Quick connect coupling red coolant return 12 Quick connect coupling blue coolant supply 13 Cooling air outlet 14 Qui...

Page 18: ...Machine description quick overview Rear view 18 099 000237 EW501 25 04 2019 4 2 Rear view Figure 4 2 ...

Page 19: ...chine fuse 6 3 A 3 Main switch machine on off 4 Connector plug TIG Welding current minus potential 5 Connecting nipple G shielding gas connection 6 Mains connection cable see 5 1 7 chapter 7 Cooling air inlet 8 External wire feed inlet Pre cut casing inlet for external wire feed 9 Quick connect coupling red coolant return 10 Quick connect coupling blue coolant supply ...

Page 20: ...cription quick overview Machine control Operating elements 20 099 000237 EW501 25 04 2019 4 3 Machine control Operating elements Unnamed operating elements have no function in this machine configuration Figure 4 3 ...

Page 21: ...h per minute 3 Display left Wire feed speed 4 Rotary dial welding parameter setting To set the wire feed speed and other welding parameters 5 Operating mode selection push button Non latched manual Latched manual Non latched automatic Latched automatic Signal light lights up in red TIG tack welding 6 Rotary knob to set the parameters for program number Selection of the program number 7 Display swi...

Page 22: ...ram PA Setting range 0 1 s to 20 0 s 0 1 s increments Used e g in connection with the super pulse function 5 Signal light wire feed speed of reduced main program PB 6 Signal light duration of reduced main program PB Setting range 0 1 s to 20 0 s 0 1 s increments Use in conjunction with the SuperPulse function or tack welding 7 Signal light wire return Setting range from 0 0 mm to 50 0 mm 8 Super p...

Page 23: ...e description quick overview Machine control Operating elements 099 000237 EW501 25 04 2019 23 4 3 2 Operating elements in the machine Figure 4 5 Item Symbol Description 0 1 Wire spool holder 2 Wire feed unit ...

Page 24: ...Machine description quick overview Connection plan 24 099 000237 EW501 25 04 2019 4 4 Connection plan Tetrix 3 AC tigSpeed drive 45 coldwire TIG 450W CW 12POL 1 AC AC AC HP HP Figure 4 6 ...

Page 25: ...tential workpiece Coolant inlet colour coded Coolant outlet colour coded HP Hose package HP hose package Control cable cold wire 5 pole signal input Control cable cold wire 5 pole signal input 1 AC Supply voltage connection 1 phase 3 AC Supply voltage connection 3 phase Welding torch control cable connection 12 pole Welding torch control cable 12 pole Wire feeding ...

Page 26: ...ne is switched off Read and observe the documentation to all system and accessory components 5 1 Transport and installation WARNING Risk of accident due to improper transport of machines that must not be lifted Do not lift or suspend the machine The machine can drop and cause injuries The handles straps or brackets are suitable for transport by hand only The machine must not be suspended or lifted...

Page 27: ... 2 2 Transport and storage Storage in a closed room temperature range of the ambient air 30 C to 70 C 22 F to 158 F 1 Relative humidity up to 90 at 20 C 68 F 1 Ambient temperature dependent on coolant Observe the coolant temperature range of the torch coo ling 5 1 3 Machine cooling Insufficient ventilation results in a reduction in performance and equipment damage Observe the ambient conditions Ke...

Page 28: ...with HF igniter TIG for as long as pos sible 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 in termediate hose package torch lead Figure 5 2 Use an individual welding lead to the workpiece for each weldi...

Page 29: ...Check that all welding current connections are firmly secured and electrical connections are in perfect condition Set up attach or suspend all conductive power source components such as casing trans port vehicles and crane frames so they are insulated Do not place any other electronic devices such as drills or angle grinders on the power source transport vehicle or crane frames unless they are ins...

Page 30: ...al conductor Figure 5 6 Legend Item Designation Colour code L Outer conductor brown N Neutral conductor blue PE Protective conductor green yellow Insert mains plug of the switched off machine into the appropriate socket 5 1 8 Welding torch cooling system Insufficient frost protection in the welding torch coolant Depending on the ambient conditions different liquids are used for cooling the welding...

Page 31: ...duct portfolio with standard lengths A straight kink free installation is to be ensured taking into account the max delivery height Pump Pmax 3 5 bar 0 35 MPa Power source Hose package Wire feeder miniDrive Welding torch Max Compact 25 m 82 ft 5 m 16 ft 30 m 98 ft 20 m 65 ft 5 m 16 ft Decompact 25 m 82 ft 5 m 16 ft 15 m 49 ft 10 m 32 ft 5 m 16 ft Pump Pmax 4 5 bar 0 45 MPa Power source Hose packag...

Page 32: ...ckage 3 Connector plug TIG Welding current minus potential 4 Connector plug 5 pole Control lead 5 Connecting nipple G shielding gas connection 6 Quick connect coupling red coolant return 7 Quick connect coupling blue coolant supply Push the cable socket for the welding current TIG onto the connector plug TIG and lock by turnng to the right Lock connecting nipples of the cooling water tubes into th...

Page 33: ...oints of the intermediate hose package depend on the corresponding system configuration Depending on the system configuration suitable options for retrofitting ON are available Figure 5 8 Item Symbol Description 0 1 ON SR Combination with mobile power sources 2 ON AS SR tigSpeed Universal combination 3 ON WAK tigSpeed Combination with transport system ...

Page 34: ...tion 34 099 000237 EW501 25 04 2019 5 1 9 2 Locking the strain relief EWM intermediate hose package Figure 5 9 5 1 9 3 Control cable pin configuration Figure 5 10 Output make contact for torch trigger input of the power source floating contact ...

Page 35: ...ose bridge to establish the coolant cuit see 9 chapter Prepare welding torch according to the welding task in hand see operating instructions for the torch Figure 5 11 Item Symbol Description 0 1 Welding torch Observe additional system documents 2 Welding torch hose package 3 Wire electrode connection Welding torch wire feed 4 Quick connect coupling red coolant return 5 Quick connect coupling blue...

Page 36: ...ure nipple in the quick connect coupling and engage Insert welding torch control lead into the 12 pole connection socket and secure with the crown nut Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings Return line red to quick connect coupling red coolant return and supply line blue to quick connect coupling blue coolant supply 5 1 10 1 Control cable ...

Page 37: ...r intervals Keep all casing covers or protective caps closed during operation 5 1 11 1 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 support and fall to the ground causing damage to the machine and injuries Make sure to correctly fasten the wire spool to the wire spool support Be...

Page 38: ...11 3 Inching the wire electrode CAUTION 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 The inching speed is infinitely adjustable by simultaneously pressing the wire inching...

Page 39: ...lding wire carefully from the wire spool and insert through the wire inlet nipple over the dri ve roller grooves and the guide pipe into the capillary tube and Teflon core using guide pipe Press the clamping element with the pressure roller back downwards and fold the wire units back up again wire electrode should be in the groove on the drive roller Set the contact pressure with the adjusting nut...

Page 40: ...g and insufficient securing of shielding gas cylinders can cause serious injuries Place shielding gas cylinder into the designated holder and secure with fastening elements chain belt Attach the fastening elements within the upper half of the shielding gas cylinder The fastening elements must tightly enclose the shielding gas cylinder An unhindered shielding gas supply from the shielding gas cylin...

Page 41: ... the weld pool and may cause pores to form Adjust the shielding gas quantity to suit the welding task Slowly open the gas cylinder valve Open the pressure regulator Switch on the power source at the main switch Trigger gas test see 5 1 13 1 chapter function welding voltage and wire feed motor remain switched off no accidental arc ignition Set the relevant gas quantity for the application on the pr...

Page 42: ...e hose package 5s 0 300s Figure 5 19 5 1 14 Configuring the welding machine for mechanical arc fusion welding Before the welding machine is commissioned it has to be configured for mechanical arc fusion welding The basic settings are configured directly at the welding machine control The wire return can be adjusted if necessary ...

Page 43: ...e welding programs you can use the machine control The left hand display shows the wire feed speed the right hand display shows further parameter settings such as program number or hot wire cur rent for hotwire only The operating mode is identical for all programs The following selection is an example of use Figure 5 20 ...

Page 44: ... superPuls The EWM superPuls function enables automatic switching between two operating points in a process ENTER EXIT 3s Figure 5 21 Display Setting selection Selects superPuls Switches function on or off Switch on Switching on machine function Switch off Switching off machine function ...

Page 45: ...ing it You can choose between four operating modes see the following functional sequences Wire feeding is infinitely adjustable by means of torch triggers 3 and 4 BRT 3 and BRT 4 Figure 5 22 5 1 16 1 Explanation of symbols Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger quick pressing and releasing Shielding gas flowing I Welding performance Non latched manual Latched ma...

Page 46: ...ites Welding current flows Second cycle current BRT 1 Release The welding current ramps up to the main current AMP in the selected up slope time First cycle wire Press torch trigger 2 BRT 2 Wire electrode is fed Second cycle wire BRT 2 Release Wire electrode feeding is stopped wire electrode is returned by the set wire return value Third cycle current BRT 1 Press The main current is reduced in the...

Page 47: ...T 2 By tapping you can switch to the reduced wire feeding By pressing and releasing tapping BRT 2 again wire feeding will stop It is not necessary to keep the torch trigger pressed This is especially helpful with long welding seams Stopping the welding process Keep BRT 1 pressed for a period longer than the set tapping time The wire feeding can be stopped prematurely by pressing BRT2 For this the ...

Page 48: ...iece The arc ignites The welding current flows and immediately assumes the value of the starting current Istart HF switches off The welding current increases in the set up slope time to the main current AMP The wire electrode is fed once the delay time t start has elapsed Second cycle current Release BRT 1 Wire electrode feeding is stopped wire electrode is returned by the set wire return value Th...

Page 49: ...The wire electrode is fed once the delay time t start has elapsed 3 cycle current Press BRT 1 The main current is reduced in the selected down slope time 2 cycle wire Wire electrode feeding is stopped wire electrode is returned by the set wire return value 4 cycle current Release BRT 1 the arc extinguishes Shielding gas continues to flow in the selected gas post flow time By tapping you can switch...

Page 50: ...iece The arc ignites The welding current flows and immediately assumes the value of the starting current Istart HF switches off The welding current increases in the set up slope time to the main current AMP The wire electrode is fed once the delay time t start has elapsed Release BRT 1 Wire electrode feeding is stopped wire electrode is returned by the set wire return value The main current is red...

Page 51: ...urn Tapping time Setting range 0 0 s to 0 6 s 0 1 s increments Gas post flow time Setting range 0 0 s to 40 0 s 0 1 s increments Wire stop with manual latched operation on wire stops in the 3rd cycle off wire stops in the 4th cycle ex works 5 3 Access control To prevent people from unauthorised or inadvertent changing of the welding parameters at the machine entering values on the control can be b...

Page 52: ...s part of the machine s scope of delivery Figure 5 29 Item Symbol Description 0 1 Crossmember of the transport handle 2 Torch holder 3 Fixing screws x 4 4 Fan type lock washers Use the mounting screws to screw the torch holder onto the crossmember of the transport handle Insert the welding torch into the welding torch holder as shown ...

Page 53: ...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 it...

Page 54: ...ly tighten if ne cessary Remove any spatter Clean the wire feed rollers on a regular basis depending on the degree of soiling 6 2 2 Monthly maintenance tasks 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 Functional test Selector switches command devic...

Page 55: ...er on wheels indicates that the equipment must be collected separately This machine has to be disposed of or recycled in accordance with the waste separation systems in use According to German law law governing the distribution taking back and environmentally correct dis posal of electric and electronic equipment ElektroG used machines are to be placed in a collection system separate from unsorted...

Page 56: ...7 4 chapter Functional errors All machine control signal lights are illuminated after switching on No machine control signal light is illuminated after switching on No welding power Phase failure check mains connection fuses Several parameters cannot be set machines with access block Entry level is blocked disable access lock see 5 3 chapter Connection problems Make control lead connections and ch...

Page 57: ...zzle Replace gas nozzle Pore formation Inadequate or missing gas shielding Check shielding gas setting and replace shielding gas cylinder if necessary Shield welding site with protective screens draughts affect the welding result Use gas lens for aluminium applications and high alloy steels Unsuitable or worn welding torch equipment Check size of gas nozzle and replace if necessary Condensation hy...

Page 58: ...elding parameters to the factory settings 58 099 000237 EW501 25 04 2019 7 3 Resetting welding parameters to the factory settings All customised welding parameters that are stored will be replaced by the factory settings Figure 7 1 ...

Page 59: ...ays use the blue coolant connection which is located as deep as possible inside the system close to the coolant tank Figure 7 2 Complete the following steps to vent the welding torch Connect the welding torch to the cooling unit Switch on the welding machine Venting the welding torch starts and lasts for approx 5 to 6 minutes ...

Page 60: ...category Ⅲ Contamination level 3 protection classification IP 23 Ambient temperature 1 25 C to 40 C Machine cooling Torch cooling Fan AF gas Wire feed speed 0 3 m min to 15 m min Factory installed roll equipment 1 0 1 2 mm for steel wire Drive 4 rollers 37 mm Wire spool diameter Standardised wire spools up to 300 mm Welding torch connection Decentralised connection EMC class A Safety marking Stand...

Page 61: ...rmediate hose package for connection to equipment from other manufacturers 094 019463 00000 tigSpeed 95QMM W AW 5POL 2m Intermediate hose package water cooled filler wire incl strain relief 094 019139 00000 tigSpeed 95QMM W AW 5POL 5m Intermediate hose package water cooled filler wire incl strain relief 094 019139 00005 tigSpeed 95QMM W AW 5POL 10m Intermediate hose package water cooled filler wir...

Page 62: ...7 mm for aluminium 092 000870 00000 10 1 2 1 Conversion kit Type Designation Item no URUE AL 4ZR4R 0 8 1 0 SF Conversion kit 37 mm 4 roller drive for aluminium 092 002268 00000 URUE AL 4ZR4R 1 0 1 2 SF Conversion kit 37 mm 4 roller drive for aluminium 092 002266 00000 URUE AL 4ZR4R 1 2 1 6 SF Conversion kit 37 mm 4 roller drive for aluminium 092 002269 00000 URUE AL 4ZR4R 2 4 3 2 SF Conversion kit...

Page 63: ...rs to be set depend on the joint and welding position The welding speed as well depends on the welding task and the parameters set Figure 11 1 Item Description t Material thickness in mm Is Welding current TIG power source Dv Wire feed speed tigSpeed Hz Weave frequency tigSpeed IH Hot wire current tigSpeed Vs Welding speed Welding torch Torch angle Wire angle Wire feed angle ...

Page 64: ...5 1 0 Forehand 10 20 41 42 4 180 1 8 Forehand 10 20 41 42 6 220 2 5 Forehand 10 20 41 42 8 260 3 5 Forehand 10 20 41 42 10 280 4 5 Forehand 10 20 41 42 Fillet weld PF position Parent metal Unalloyed low alloy Welding consumable Unalloyed low alloy Ø 1 0 mm t mm Is A WF m min Hz 1 s IH A Vs cm min Welding torch Wire angle 1 5 90 0 8 Forehand 10 20 41 42 2 135 1 0 Forehand 10 20 41 42 4 180 1 8 Fore...

Page 65: ...alloyed low alloy Welding consumable Unalloyed low alloy Ø 1 0 mm t Is Wf1 tWF1 Wf2 tWF2 IH Vs Welding torch Wire angle mm A m min sec m min sec A cm min 1 5 100 1 9 0 15 0 0 off 0 35 Forehand 15 45 2 140 3 5 0 15 0 0 off 0 35 Forehand 15 45 4 190 4 0 0 15 0 0 off 0 35 Forehand 15 45 6 240 5 0 0 15 0 0 off 0 35 Forehand 15 45 8 280 6 5 0 15 0 0 off 0 35 Forehand 15 45 10 300 7 5 0 15 0 0 off 0 35 ...

Page 66: ...g torch Wire angle mm A m min sec m min sec A cm min 1 5 90 1 9 0 15 0 0 off 0 35 32 Forehand 15 45 2 135 3 5 0 15 0 0 off 0 35 38 Forehand 15 45 4 180 4 0 0 15 0 0 off 0 35 41 Forehand 15 45 6 220 5 0 0 15 0 0 off 0 35 43 Forehand 15 45 8 260 6 5 0 15 0 0 off 0 35 43 Forehand 15 45 10 280 7 5 0 15 0 0 off 0 35 48 Forehand 15 45 Fillet weld PF position Parent metal High alloy Welding consumable Hi...

Page 67: ...Appendix Searching for a dealer 099 000237 EW501 25 04 2019 67 11 2 Searching for a dealer Sales service partners www ewm group com en specialist dealers More than 400 EWM sales partners worldwide ...

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