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Replaceable parts

Wire feed rollers

099-005401-EW501

17.06.2014

Replaceable parts

CAUTION

Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes 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
products!

• Only insert and lock accessory components into the relevant connection socket when the

machine is switched off.

10.1

Wire feed rollers

10.1.1

Overview

Figure 10-1

Содержание drive 4 Basic MMA

Страница 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...

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: ...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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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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