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Safety instructions

General

8

099-005333-EW501

19.03.2014

2.3

General

DANGER

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!

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 Maintenance and Testing 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)!

WARNING

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!

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!

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Содержание alpha Q 351 Progress puls MM FDW

Страница 1: ...351 Progress puls MM FDW alpha Q 551 Progress puls MM FDW 099 005333 EW501 Observe additional system documents 19 03 2014 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group...

Страница 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...

Страница 3: ...ly 17 3 3 1 Warranty 17 3 3 2 Declaration of Conformity 17 3 3 3 Welding in environments with increased electrical hazards 17 3 3 4 Service documents spare parts and circuit diagrams 17 3 3 5 Calibrat...

Страница 4: ...ion 40 6 3 Maintenance work 40 6 4 Disposing of equipment 41 6 4 1 Manufacturer s declaration to the end user 41 6 5 Meeting the requirements of RoHS 41 7 Rectifying faults 42 7 1 Checklist for rectif...

Страница 5: ...Contents Notes on the use of these operating instructions 099 005333 EW501 19 03 2014 5...

Страница 6: ...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...

Страница 7: ...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...

Страница 8: ...pment 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 av...

Страница 9: ...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 allo...

Страница 10: ...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...

Страница 11: ...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...

Страница 12: ...during movement and set up Tilt resistance is guaranteed up to an angle of 10 according to EN 60974 A2 Set up and transport the machine on level solid ground Secure add on parts using suitable equipme...

Страница 13: ...ft all lifting eyes simultaneously When using retrofitted craning frames etc always use at least two lifting points positioned as far apart as possible observe option description Avoid any jerky movem...

Страница 14: ...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...

Страница 15: ...energy MAG welding X ray proof welding of pipelines and pipework without lack of fusion Root pass and fill and final pass with or without air gap Low and high alloy steels with solid and cored wires...

Страница 16: ...014 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 alpha Q 351 551 351 D 551 D 351 2DV 551 2D...

Страница 17: ...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...

Страница 18: ...Machine description quick overview Front view 18 099 005333 EW501 19 03 2014 4 Machine description quick overview 4 1 Front view Figure 4 1...

Страница 19: ...ooling air inlet 6 Wheels guide castors 7 Coolant tank 8 Coolant tank cap 9 Automatic cut out of coolant pump key button press to reset a triggered fuse 10 welding current connection socket MIG MAG we...

Страница 20: ...Machine description quick overview Rear view 20 099 005333 EW501 19 03 2014 4 2 Rear view Figure 4 2...

Страница 21: ...welding current Standard MIG MAG welding intermediate hose package 6 Connection socket welding current Connection for welding current plug from intermediate hose package MIG MAG flux cored wire weldi...

Страница 22: ...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...

Страница 23: ...AUTION 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...

Страница 24: ...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...

Страница 25: ...3 2014 25 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...

Страница 26: ...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...

Страница 27: ...al filling process the cooling unit tank should be topped up as necessary The unit is supplied ex works with a minimum level of coolant Figure 5 4 Item Symbol Description 0 1 Coolant tank cap 2 Coolan...

Страница 28: ...etwork has to be suitable for operating devices according to protection class 1 5 7 1 Mains configuration NOTE The machine may be connected to a three phase system with four conductors and an earthed...

Страница 29: ...ead should be connected to the welding current socket Observe the information from the electrode manufacturer Figure 5 6 Item Symbol Description 0 1 Wire feed unit 2 Intermediate hose package 3 Interm...

Страница 30: ...ling 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 upp...

Страница 31: ...e regulator 2 Shielding gas cylinder 3 Output side of the pressure regulator 4 Cylinder valve Place the shielding gas cylinder into the relevant cylinder bracket Secure the shielding gas cylinder usin...

Страница 32: ...rent 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 8...

Страница 33: ...re connected to the Euro torch connector of the wire feeder only To do so the welding current lead of the intermediate hose package must be connected to the welding current connection at the rear of t...

Страница 34: ...e welding current connection If fitted Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings Return line red to quick connect coupling red coolant return an...

Страница 35: ...d surface 5 12 1 Connecting the electrode holder and workpiece lead NOTE Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging Figure 5 11 Item Symbol D...

Страница 36: ...l Please note the relevant documentation of the accessory components 5 14 Interfaces for automation DANGER Do not carry out any unauthorised repairs or modifications To avoid injury and equipment dama...

Страница 37: ...in the welding machine Contact open welding current off F Output 0 V Reference potential G P Output I 0 Power relay contact galvanically isolated max 15 V 100 mA H Output Uist Welding voltage measure...

Страница 38: ...if the PC is connected incorrectly Not using the SECINT X10USB interface results in equipment damage or faults in signal transmission The PC may be destroyed due to high frequency ignition pulses Int...

Страница 39: ...ve the torch from the hose package Never clamp the torch body in a vice or similar as this can cause the torch to be irreparably destroyed If damage occurs to the torch or to the hose package which ca...

Страница 40: ...panying supplementary sheets Machine and Company Data Maintenance and Testing Warranty A periodic test according to IEC 60974 4 Periodic inspection and test has to be carried out In addition to the re...

Страница 41: ...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...

Страница 42: ...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...

Страница 43: ...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...

Страница 44: ...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...

Страница 45: ...gle JOB NOTE All customised welding parameters that are stored will be replaced by the factory settings EXIT RESET ENTER 3 s 3 s 3 s JOB LIST JOB LIST Figure 7 1 Display Setting selection Reset to fac...

Страница 46: ...will be ended when no changes are done after 3 sec 7 4 General operating problems 7 4 1 Interface for automated welding WARNING No function of the external interrupt equipment emergency stop switch If...

Страница 47: ...t circuit 099 005333 EW501 19 03 2014 47 7 5 Vent coolant circuit NOTE To vent the cooling system always use the blue coolant connection which is located as deep as possible inside the system close to...

Страница 48: ...ty fuse slow blow 3 x 25 A Mains connection lead H07RN F4G6 Maximum connected load 13 9 kVA 15 0 kVA 10 6 kVA Recommended generator rating 20 3 kVA cos 0 99 Insulation class protection classification...

Страница 49: ...nnection lead H07RN F4G6 Maximum connected load 28 8 kVA 29 2 kVA 22 2 kVA Recommended generator rating 39 4 kVA cos 0 99 Insulation class protection classification H IP 23 Ambient temperature 25 C to...

Страница 50: ...KF 23E 200 Coolant 10 C 200 litres 094 000530 00001 KF 37E 10 Coolant 20 C 9 3 l 094 006256 00000 KF 37E 200 Coolant 20 C 200 l 094 006256 00001 DM AR MIX 35L MIN Manometer pressure regulator 094 000...

Страница 51: ...RV 7POL 10 m Extension connecting cable 092 000201 00000 FRV 7POL 20 m Extension connecting cable 092 000201 00001 FRV 7POL 25M Extension connecting cable 092 000201 00007 9 5 Computer communication T...

Страница 52: ...Appendix A Overview of EWM branches 52 099 005333 EW501 19 03 2014 10 Appendix A 10 1 Overview of EWM branches...

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