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Accessories

Cooling units

099-005366-EW501

31.07.2014

9.7

Cooling units

Type

Designation

Item no.

RK1

Reverse cooling unit

094-002283-00000

RK2

Reverse cooling unit

094-002284-00000

RK3

Reverse cooling unit

094-002285-00000

cool82 U44

Cooling module for robot welding machines

090-008268-00502

cool82 U45

Cooling module for robot welding machines

090-008280-00502

9.8

Wire feed units

Type

Designation

Item no.

M drive 4 Rob 2 WE

MIG WF unit

090-004999-00502

M drive 4 Rob 2 WI

MIG WF unit

090-004999-00503

M drive 4 Rob 2 ZT

Robot intermediate drive

090-005137-00502

M drive 4 Rob 2 MF

MIG WF unit

090-005000-00502

M drive 4 Rob 3 RE

MIG WF unit

090-005110-00502

M drive 4 Rob 3 LI

MIG WF unit

090-005111-00502

Содержание alpha Q 352 puls MM

Страница 1: ...r automated applications alpha Q 352 552 puls MM 099 005366 EW501 Observe additional system documents 31 07 2014 Register now For your benefit Jetzt Registrieren und Profitieren www ewm group com Deta...

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: ...ding in environments with increased electrical hazards 16 3 2 4 Service documents spare parts and circuit diagrams 16 3 2 5 Calibration Validation 16 4 Machine description quick overview 17 4 1 Front...

Страница 4: ...pe 53 5 16 5 1 Program or control voltage mode 53 5 16 5 2 Program sequence 54 5 16 5 3 superPuls 55 5 16 6 MIG MAG functional sequences operating modes 56 5 16 6 1 Explanation of signs and functions...

Страница 5: ...eting the requirements of RoHS 72 7 Rectifying faults 73 7 1 Checklist for rectifying faults 73 7 2 Error messages 75 7 3 Error messages RC Panel 77 7 3 1 Interface for automated welding 78 7 4 Displa...

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: ...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 T...

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: ...ard 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 foll...

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: ...gap bridging and positional welding 3 1 1 3 coldArc Heat reduced low spatter short arc for high dimensional stability welding and brazing plus root welding with excellent gap bridging capabilities 3...

Страница 16: ...d 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 hazar...

Страница 17: ...Machine description quick overview Front view 099 005366 EW501 31 07 2014 17 4 Machine description quick overview 4 1 Front view Figure 4 1...

Страница 18: ...9 005366 EW501 31 07 2014 Item Symbol Description 0 1 Lifting lug 2 PC interface serial D Sub connection socket 9 pole 3 Machine control See 4 3 Machine control Operating elements chapter 4 Main switc...

Страница 19: ...Machine description quick overview Rear view 099 005366 EW501 31 07 2014 19 4 2 Rear view Figure 4 2...

Страница 20: ...5 7 pole connection socket digital Wire feed unit connection 6 12 pole connection socket analogue Connection socket for analogue control signals collision protection etc between the welding torch and...

Страница 21: ...unter Selection of further welding parameters in lower programming levels 2 Display 16 digit Display of all welding parameters and their values 3 Switching of the digital display Buttons right Welding...

Страница 22: ...ram sequence is shown Outside the values can be selected and welding parameters changed by means of the rotary dial Gas pre flows 0 0 to 20 0 sec Start program WFstart 0 to 200 Ustart Start time 0 0 t...

Страница 23: ...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 24: ...ons 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 Pr...

Страница 25: ...099 005366 EW501 31 07 2014 25 5 2 Connection plan 3 AC Cool 82 M drive 4 Rob 2 AC Fassf rderung 7 pol 12 pol 5 pol 8 pol 5 pol SPS CU ROB 19 pol RINTX12 BUSINTX11 7 pol 12 pol 7 pol 19 pol 19 pol AI...

Страница 26: ...elding machine supply voltage Welding current plus potential 19 pol 19 pole mechanised welding interface 12 pol Wire feed unit control lead 12 pole 7 pol Wire feed unit control lead RINTX12 BUSINTX11...

Страница 27: ...mponents 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 o...

Страница 28: ...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 29: ...7 2014 29 NOTE Use an individual welding lead to the workpiece for each welding machine Figure 5 3 NOTE Fully unroll welding current leads torch hose packages and intermediate hose packages Avoid loop...

Страница 30: ...ter See 9 Accessories chapter Replace coolant as necessary if frost protection is inadequate NOTE The disposal of coolant must be carried out according to official regulations and observing the releva...

Страница 31: ...ssory components Figure 5 5 Item Symbol Description 0 1 8 pole connection socket Cooling unit control lead 2 Connection socket 5 pole Cooling unit voltage supply Insert and lock the 8 pole control lea...

Страница 32: ...etwork has to be suitable for operating devices according to protection class 1 5 9 1 Mains configuration NOTE The machine may be connected to a three phase system with four conductors and an earthed...

Страница 33: ...nnection socket for analogue control signals collision protection etc between the welding torch and the power source 4 Connection socket welding current MIG MAG welding Welding current to wire feed to...

Страница 34: ...welding torch With other hose package lengths it is necessary to carry out a voltage correction to optimise welding properties The voltage correction value can be set close to zero by means of re matc...

Страница 35: ...are to be operated from a single power source for example a second alignment with parameter Rl2 must be performed To do so switch the wire feeder using the appropriate interface 3 Alignment measuremen...

Страница 36: ...urrent 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...

Страница 37: ...compressed air Place shielding gas cylinders in the holders provided for them and secure with fixing devices Avoid heating the shielding gas cylinder CAUTION Faults in the shielding gas supply An unhi...

Страница 38: ...ose on pressure regulator to be gas tight Fit the gas hose and G1 4 crown nut onto the relevant connection on the welding machine and fit the wire feed unit if present on this version 5 13 2 Setting i...

Страница 39: ...found in the operating instructions for the relevant accessory components Accessory components are detected automatically after the power source is switched on The interfaces can be operated directly...

Страница 40: ...necting digital accessory components 2 Switching cabinet 3 Robot interface Tetrix Phoenix alpha Q RINT X12 4 Industrial bus interface Tetrix Phoenix alpha Q BUSINT X11 5 Interface casing 6 Connection...

Страница 41: ...ial D Sub connection socket 9 pole 2 Connection cable 9 pole serial 3 Windows PC 4 RC300 tablet PC 5 USB connection 6 SECINT X10 USB CAUTION Equipment damage or faults may occur if the PC is connected...

Страница 42: ...essory components 2 Windows PC 3 RC300 tablet PC 4 SECINT X10 USB 5 Connection cable 9 pole serial 6 PCINT X10 7 Connection cable 7 pole Connection between switching cabinet and power source CAUTION E...

Страница 43: ...l power sources Figure 5 14 Item Symbol Description 0 1 7 pole connection socket digital For connecting digital accessory components 2 Windows PC 3 WELDQAS welding data monitoring and documentation sy...

Страница 44: ...pplications control inputs and galvanically isolated relay contacts are available on the interface for mechanised welding CAUTION Equipment damage due to unshielded control leads Unshielded control le...

Страница 45: ...PCB M320 1 of the welding machine is open Connection with potential free contact F Output 0V G P Output IGR0 Power relay contact I 0 to the user Potential free 15 V 100 mA H Output Uist Uact 10 V 100...

Страница 46: ...t be unplugged on PCB M320 1 in the welding machine Contact open welding current switched off D NC E Gasd sensensor 1 F NC G NC H NC J NC K NC M NC 5 14 8 Sensor Voltage Outside the welding process th...

Страница 47: ...t be changed 5 15 1 Welding data display To the left and right of the LCD display on the control there are 2 arrow keys on each side for selecting the welding parameter to be displayed The button is u...

Страница 48: ...ogram and the gas pre flow time wire creep slope times wire burn back and many more are preset for a variety of applications but can be modified where required On the control panel the most important...

Страница 49: ...Operating element Action Result Display example X x Select Job new The signal light displays the selection Verf MIG 1 x Select Welding process Verf MIG n x Select Welding process Verf MIG 1 x Select M...

Страница 50: ...CrNi Ar 91 99 251 12 0 252 12 0 253 6 0 You can make use of these properties after selecting the forceArc process see the Selecting a MIG MAG welding task chapter As with pulse arc welding it is impo...

Страница 51: ...Manual and automated applications coldArc welding to Wire mm 0 8 0 9 1 1 2 1 6 Material Gas JOB JOB JOB JOB JOB CrNi Ar 91 99 51 7 0 52 6 0 AlMg Ar 100 55 8 0 56 8 0 ALSi Ar 100 59 8 0 60 6 0 AL99 Ar...

Страница 52: ...n all positions Figure 5 19 Root welding for metal sheets and pipes in all positions Unalloyed and low alloy steels as well as high tensile fine grained steels Manual and automated applications pipeSo...

Страница 53: ...ing point can be set using control voltages PROG 0 via the robot interface RINTX11 BUSINTX10 Different welding tasks or positions on a workpiece demand various welding outputs operating points or weld...

Страница 54: ...d and changed on the control panel Graphic Symbol Parameter Value Gas pre flows 0 0 to 20 0 sec Ignition program Wire speed Voltage correction WFstart 0 to 200 or Ustart 9 9 V to 9 9 V Change with but...

Страница 55: ...d reduced main program PB This function is used in the very thin metal sheet range for example to reduce the heat input in a targeted way Selection on the operating panel Operating element Action Resu...

Страница 56: ...flow and burn back etc for numerous applications although these can also be changed if required 5 16 6 1 Explanation of signs and functions Symbol Meaning Start of welding End of welding Shielding ga...

Страница 57: ...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 Changeover to pre selected wire speed mai...

Страница 58: ...uns at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Start the super pulse function beginning with main program PA The welding parameters swit...

Страница 59: ...s Wire feed motor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current is flowing start program PSTART for the time tstart Slope to main program PA...

Страница 60: ...makes contact with the workpiece welding current is flowing start program PSTART for the time tstart Slope on main program PA Start the super pulse function beginning with main program PA The welding...

Страница 61: ...gram PSTART reduction of cool points at the start of the seam Main program PA continuous welding Reduced main program PB targeted heat reduction End program PEND minimisation of end craters via target...

Страница 62: ...pe duration from PB to PA 0 00s to 20 0s PEND end program tSe Slope duration from PA to PEND 0 0s to 20s DVend Wire speed 1 to 200 Uend Arc length correction 9 9V to 9 9V tend Duration superpulse 0 0s...

Страница 63: ...lay Meaning explanation Setting range curr prg X Active main program A 0 to 15 P0 U2 0 0V Arc length correction offset Wire feed unit 9 9V to 9 9V P1 15 UK 2 0V Limitation of the setting range for the...

Страница 64: ...4 099 005366 EW501 31 07 2014 5 17 Special Mode mode 5 17 1 Selection NOTE Combination of buttons shown must be selected without pauses Operating element Action Result Display 1 x Select Special Mode...

Страница 65: ...hat they represent a percentage of the wire feed speed DV2 main program A that has been set All wire feed speeds can also be specified as absolute values independent of other values To do this the abs...

Страница 66: ...e defined or user defined JOB JOB Nr JOB number akt Prg Program number Mode Operating mode Schweiss Welding type JOB Text Text information relating to the JOB can be edited using PC 300 Net software W...

Страница 67: ...two memory sectors 128 factory set pre programmed fixed jobs jobs 1 to 128 Each welding task is assigned a JOB number 1 to 128 128 freely definable JOBs JOBs 129 to 256 Each job can also be loaded dir...

Страница 68: ...the buttons Up and Down right Load JOB xxx 1 x JOB has been loaded Load JOB xxx 3 x Machine returns to Display mode 5 20 3 Resetting an existing JOB to the factory setting Reset JOB NOTE If a pre pro...

Страница 69: ...ting expert model parameters Operating element Action Result 1 x Select expert model parameters 1 x 1 x 2 x 5 21 2 Selecting variables 5 model points Operating element Action Result 1 x Select model p...

Страница 70: ...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...

Страница 71: ...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...

Страница 72: ...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 73: ...ontrol lead connections and check that they are fitted correctly Insufficient coolant flow Check coolant level and refill if necessary Wire feed problems Unsuitable or worn welding torch equipment Adj...

Страница 74: ...replace if necessary Adjust wire guide to material in use blow through and replace if necessary Material inclusions in the tungsten electrode due to contact with filler material or workpiece Regrind...

Страница 75: ...nge of application signal of the power source has not been updated Phoenix alpha Q Te trix Yes 4 Wire feed error Phoenix alpha Q Te trix Yes 5 Inverter inverter emergency stop circuit temperature erro...

Страница 76: ...as been attempted in a system supporting the function to switch double wire feeders Phoenix alpha Q Yes 54 Reducing the open circuit voltage to the set values failed for power sources with voltage red...

Страница 77: ...coolant circuit rectify the leak and top off the coolant Coolant pump is not working check excess current trigger on air cooling unit Error 5 Wi Spe x Wire feeder speedometer error Check the wire fee...

Страница 78: ...arExpert Progress M3 11 alpha Q Concept Basic Basic S Synergic Synergic S Progress M3 71 Picomig 305 not possible c The error message can only be reset by switching the machine off and on again 7 3 1...

Страница 79: ...versions display System bus ID printed circuit board 0 0 0 0 Version number System bus ID printed circuit board and version number are separated by a colon List of the software End of the list of sof...

Страница 80: ...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...

Страница 81: ...20 A Duty cycle at 20 C ambient temperature 60 DC 550 A 100 DC 350 A 420 A Load cycle 10 min 60 DC 6 min welding 4 min pause Open circuit voltage 93 V Mains voltage tolerance 3 x 400 V 25 to 20 Freque...

Страница 82: ...01 ON ZWIPA CONNECTION Retrofit option for third party INTPA strain relief 094 007890 00000 9 4 Transport systems Type Designation Item no PALETTE ROB XX2 Transport pallet for use with robots 090 0082...

Страница 83: ...robot welding machines 090 008268 00502 cool82 U45 Cooling module for robot welding machines 090 008280 00502 9 8 Wire feed units Type Designation Item no M drive 4 Rob 2 WE MIG WF unit 090 004999 005...

Страница 84: ...Circuit diagrams alpha Q 352 552 Puls 84 099 005366 EW501 31 07 2014 10 Circuit diagrams 10 1 alpha Q 352 552 Puls NOTE Original format circuit diagrams are located inside the machine Figure 10 1...

Страница 85: ...Circuit diagrams alpha Q 352 552 Puls 099 005366 EW501 31 07 2014 85 Figure 10 2...

Страница 86: ...Appendix A JOB List 86 099 005366 EW501 31 07 2014 11 Appendix A 11 1 JOB List...

Страница 87: ...Appendix A JOB List 099 005366 EW501 31 07 2014 87...

Страница 88: ...Appendix A JOB List 88 099 005366 EW501 31 07 2014...

Страница 89: ...Appendix A JOB List 099 005366 EW501 31 07 2014 89...

Страница 90: ...Appendix A JOB List 90 099 005366 EW501 31 07 2014...

Страница 91: ...Appendix A JOB List 099 005366 EW501 31 07 2014 91...

Страница 92: ...Appendix A JOB List 92 099 005366 EW501 31 07 2014...

Страница 93: ...Appendix A JOB List 099 005366 EW501 31 07 2014 93...

Страница 94: ...Appendix A JOB List 94 099 005366 EW501 31 07 2014...

Страница 95: ...Appendix B Overview of EWM branches 099 005366 EW501 31 07 2014 95 12 Appendix B 12 1 Overview of EWM branches...

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