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Intended use

Part of the complete documentation

099-5TLPXQ-EW501

29.01.2021

3.4 Part of the complete documentation

This document is part of the complete documentation 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 3-1

The illustration shows a general example of a welding system.

Item Documentation

A.1

Wire feeder

A.2

Remote adjuster

A.3

Controller

A.4

Power source

A.5

Welding torch

Complete documentation

Содержание LP-XQ

Страница 1: ...Operating instructions EN Control LP XQ M3 7X N 099 5TLPXQ EW501 Observe additional system documents 29 01 2021...

Страница 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 f...

Страница 3: ...Favourites 22 5 Functional characteristics 23 5 1 Shielding gas supply shielding gas cylinder for welding machine 23 5 1 1 Shielding gas volume settings 23 5 1 2 Gas test 23 5 1 3 Purge hose package...

Страница 4: ...gment display P3 57 5 10 1 4 Program limit P4 57 5 10 1 5 Special cycle in the operating modes special latched and non latched P5 58 5 10 1 6 Correction operation threshold value setting P7 58 5 10 1...

Страница 5: ...ftware version 65 6 2 Error messages power source 65 6 3 Warnings 68 6 4 Resetting JOBs welding tasks to the factory settings 69 6 4 1 Resetting a single JOB 69 6 4 2 Resetting all JOBs 69 7 Appendix...

Страница 6: ...s 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 ope...

Страница 7: ...tch 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 gr...

Страница 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...

Страница 9: ...temperatures 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 excessi...

Страница 10: ...ts specified 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 us...

Страница 11: ...placement 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...

Страница 12: ...on 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 powe...

Страница 13: ...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...

Страница 14: ...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 sys...

Страница 15: ...control sections For description purposes the machine control has been divided into two sections A B to ensure maximum clarity The setting ranges for the parameter values are summarised in the paramet...

Страница 16: ...from the welding task list JOB LIST see 5 2 3 chapter 2 Rotary knob click wheel for welding power Setting the welding power see 5 2 5 chapter Setting various parameters values depending on the presel...

Страница 17: ...Potential and gas free return of the wire electrode 10 Wire inching push button Potential and gas free inching of the wire electrode see 5 2 1 chapter 11 End Signal light wire reserve sensor ex works...

Страница 18: ...rams or welding power switching by Display right push button Furthermore dynamics and depending on the preselection various welding parameter valuesare displayed Parameter times or hold values see 4 2...

Страница 19: ...he first one Figure 4 4 MIG MAG Parameter Nominal values 1 Actual values 2 Hold values 3 Welding current Material thickness Wire feed speed Welding voltage Welding power Motor current Shielding gas TI...

Страница 20: ...er For example a change in wire feed speed of 0 1 m min and a selected wire diameter of 0 8 mm results in a smaller change in the current or thickness of material than a change in wire feed speed of 0...

Страница 21: ...and the cur rent device settings are identical Signal light is red Favourite loaded but settings of the Favourite and the cur rent device settings are not identical for example the operating point has...

Страница 22: ...5 3 Deleting saved Favourites Figure 4 8 Press and hold the favourite memory push button After 2 seconds the signal light of the favourite status turns green after another 5 s the signal light starts...

Страница 23: ...t see 5 1 2 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 pressure regulator Setting inst...

Страница 24: ...s set by simultaneously pressing the wire inching button and turning the left click wheel Figure 5 3 5 2 2 Wire return The wire return function is used to retract the wire electrode without tension an...

Страница 25: ...namics if necessary 5 2 4 Basic welding parameters The user must first determine the basic parameters material type wire diameter and shielding gas type of the welding system These basic parameters ar...

Страница 26: ...forceArc wiredArc rootArc und coldArc if there is a corresponding combination of the basic parameters The pro cess change will also change the JOB number but the basic parameters remain unchanged Fig...

Страница 27: ...in the welding current generates current pulses in the arc which lead to a 1 drop per pulse of material transfer The result is an almost spatter free process suitable for welding of all materi als in...

Страница 28: ...al thickness workpiece Set the measured value e g 5 mm at the machine control This set value corresponds to a specific wire feed speed Switching the display to this parameter will show the associated...

Страница 29: ...ng task in hand by 9 9 V Figure 5 10 5 2 5 3 Arc dynamics choke effect This function can be used to adjust the arc between a narrow hard arc with deep penetration positive values and a wide and soft a...

Страница 30: ...piece require different welding programs operating points The following parameters are stored in each program Wire feed speed and voltage correction welding power Operating mode welding type and dynam...

Страница 31: ...ynamics M3 7 I J Wire feeder control P0 P1 15 PC 300 NET Software P0 P1 15 MT Up Down Welding torch P0 P1 9 MT 2 Up Down Welding torch P0 P1 15 MT PC 1 Welding torch P0 P1 15 MT PC 2 Welding torch P0...

Страница 32: ...for operating points are made manually here Changes to the welding parameters are saved immediately 5 2 7 2 Program sequence Certain materials aluminium for example require special functions for relia...

Страница 33: ...creep Wire burn back Gas pre flows Gas post flows Non latched Special non latched Latched Special latched t Time PSTART Ignition program PA Main program PB Reduced main program PEND End program t2 Sp...

Страница 34: ...lding 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 Change over to pre selected wire spe...

Страница 35: ...ire 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 St...

Страница 36: ...wire electrode makes contact with the workpiece welding current is flowing start program PSTART spot time starts Slope to main program PA After the set spot time elapses slope goes to end program PEN...

Страница 37: ...otor runs at creep speed Arc ignites after the wire electrode makes contact with the workpiece welding current flows Change over to pre selected WF speed main program PA Step 2 Release torch trigger n...

Страница 38: ...set time tSTART elapses and at the latest when the torch trigger is released Tapping1 can be used to change over to the reduced main program PB Repeated tapping will switch back to the main program PA...

Страница 39: ...he slope on main program PA is given at the earliest after the set time tSTART elapses and at the latest when the torch trigger is released Tapping pressing the torch trigger for less than 0 3 sec cha...

Страница 40: ...A A B A Figure 5 24 Display Setting selection Ignition current Setting range in percent depending on main current Setting range absolute Imin to Imax Correction of arc length in start program PSTART...

Страница 41: ...nally stable and powerful arc with deep fusion penetration for the upper power range Figure 5 25 Smaller included angle due to deep penetration and directionally stable arc Excellent root and sidewall...

Страница 42: ...rfect arc length stability even in difficult applications and positional welding With a GMAW arc the welding current AMP changes with the change of the stick out If for instance the stick out is exten...

Страница 43: ...a terials being used Equip the welding torch and torch hose package to suit the task and the operating instructions for the welding torch This function can only be enabled with the PC300 NET software...

Страница 44: ...persons for repair work trained service personnel Dangers resulting from failure to perform test after conversion Before reconnection Inspection and Testing during Operation according to IEC BS EN 60...

Страница 45: ...ce so that the arc extinguishes 5 3 3 Operating modes functional sequences 5 3 3 1 Explanation of signs and functions Symbol Meaning Press torch trigger Release torch trigger Tap torch trigger press b...

Страница 46: ...Special non latched Figure 5 35 Selection Select non latched special mode Step 1 Press and hold torch trigger Shielding gas is expelled gas pre flows The arc is ignited using liftarc Welding gas flows...

Страница 47: ...erating mode Step 1 Press and hold torch trigger Shielding gas is expelled gas pre flows The arc is ignited using liftarc Welding current flows with pre selected setting Step 2 Release torch trigger n...

Страница 48: ...setting in start program PSTART Step 2 Release torch trigger Slope on main program PA The slope on main program PA is given at the earliest after the set time tSTART elapses and at the latest when th...

Страница 49: ...2021 49 5 4 MMA welding 5 4 1 Welding task selection Figure 5 38 5 4 1 1 Welding current setting Figure 5 39 5 4 2 Arcforce Figure 5 40 Setting Negative values rutile electrode types Values at zero ba...

Страница 50: ...oid welding errors caused by too much gas blast or insufficient shielding gas shielding gas cylinder empty or gas supply interrupted The required gas flow rate can be controlled by the user and correc...

Страница 51: ...ode in programs 1 15 No welding task switching JOB block operation P16 is possible No change of special parameters except P10 Restart is required Saving or deleting favourites is locked 5 7 Voltage re...

Страница 52: ...B B B B B Figure 5 43 Display Setting selection Lead resistance 1 Lead resistance for the first welding circuit 0 m 60 m 8 m ex works Lead resistance 2 Lead resistance for the second welding circuit 0...

Страница 53: ...m water cooled welding torch With other hose package lengths it is ne cessary to carry out a voltage correction to optimise welding properties The voltage correction value can be set close to zero by...

Страница 54: ...value can be between 0 m and 40 m The new value is immediately saved without requiring further confirmation If no va lue is shown on the right hand display then measurement failed The measurement must...

Страница 55: ...3 s ramp time ex works Block program 0 0 P0 enabled 1 P0 blocked Ex works Display mode for Up Down welding torch with one digit 7 segment display two keys 0 normal display ex works program number wel...

Страница 56: ...ies Lower limit remote JOB switching JOB range of the function torches PM 2U D PM RD2 Lower limit 129 ex works Upper limit remote JOB switching JOBarea of the function torch PM 2U D PM RD2 Upper limit...

Страница 57: ...a ramp function to 6 0 m min The ramp time can be set between two ranges During wire inching the speed can be changed by means of the welding power rotary knob Changing the speed has no effect on the...

Страница 58: ...ately for each program The correction range can be maximum 30 of the wire speed and 9 9 V welding voltage Figure 5 46 Example for the operating point in correction mode The wire speed in one program 1...

Страница 59: ...l the t3 time has elapsed The program then switches automa tically to absolute program 4 Accessory components such as remote controls or special torches may not be connected Program switching at the w...

Страница 60: ...welding start follows and not PA1 This setting can also be combined with P17 5 10 1 8 Latched special latched tap start P9 In latched tap start operating mode it is possible to switch straight to the...

Страница 61: ...s one after the other and adjust para meters individually Special parameters P13 to the lower limit and Adjust special parameters P14 to the upper limit of the destination JOBs Set switch Program or U...

Страница 62: ...r special parameter P2 1 JOB 0 can be selected JOBs 1 9 Nine JOBs can be called up in each special JOB see table Nominal values for wire speed arc correction dynamics etc must be defined in advance in...

Страница 63: ...parameter values are identical for all JOBs except for special JOBs SP1 SP2 and SP3 5 10 1 21Correction or nominal voltage display P24 When setting the arc correction using the right hand rotary knob...

Страница 64: ...ing power rotary knob P30 Function not active The rotary knob is locked use the welding parameters push button to select the welding parameters Function active Rotary knob can be used to select the we...

Страница 65: ...machine errors and inform service staff as necessary If multiple errors occur these are displayed in succession Document machine warning and inform service personnel if required If there are several e...

Страница 66: ...nection 11 Quick shut down Removing the logical signal ro bot ready during the process Eliminate errors on the higher level control 22 Coolant excess temperature 3 Coolant is overheating 70 C 158 F 1...

Страница 67: ...ement 56 Mains phase failure One phase of the mains voltage has failed Check mains connection mains plug and mains fuses 57 Slave tacho er ror Wire feeder fault slave drive Check connectors cables con...

Страница 68: ...ng circuit The welding circuit inductance is too high for the selected welding task 10 Partial inverter One of several partial inverters is not supplying welding cur rent 11 Excess temperature coolant...

Страница 69: ...setting JOBs welding tasks to the factory settings All customised welding parameters that are stored will be replaced by the factory settings 6 4 1 Resetting a single JOB 7s 5s 5s Figure 6 1 6 4 2 Res...

Страница 70: ...ulse CrNi 19 12 3 Nb 1 4576 Ar 97 5 CO2 2 5 M12 1 6 30 Standard GMAW pulse CrNi 18 8 1 4370 Ar 97 5 CO2 2 5 M12 0 8 31 Standard GMAW pulse CrNi 18 8 1 4370 Ar 97 5 CO2 2 5 M12 1 0 32 Standard GMAW pul...

Страница 71: ...g4 5Mn Ar 100 I1 1 6 78 Standard GMAW pulse AlMg4 5Mn Ar 70 He 30 I3 0 8 79 Standard GMAW pulse AlMg4 5Mn Ar 70 He 30 I3 1 0 80 Standard GMAW pulse AlMg4 5Mn Ar 70 He 30 I3 1 2 81 Standard GMAW pulse...

Страница 72: ...razing CuSi Ar 100 I1 1 2 117 Brazing CuSi Ar 100 I1 1 6 118 Brazing CuAl Ar 97 5 CO2 2 5 M12 0 8 119 Brazing CuAl Ar 97 5 CO2 2 5 M12 1 0 120 Brazing CuAl Ar 97 5 CO2 2 5 M12 1 2 121 Brazing CuAl Ar...

Страница 73: ...2 18 M21 1 6 182 coldArc G3Si1 G4Si1 CO2 100 C1 0 8 183 coldArc G3Si1 G4Si1 CO2 100 C1 0 9 184 coldArc G3Si1 G4Si1 CO2 100 C1 1 0 185 coldArc G3Si1 G4Si1 CO2 100 C1 1 2 188 GMAW Non synergic Special S...

Страница 74: ...2 18 M21 1 2 244 Flux cored wire rutile FCW CrNi Rutile Ar 82 CO2 18 M21 1 6 245 forceArc forceArc puls Al99 Ar 100 I1 1 2 246 forceArc forceArc puls Al99 Ar 100 I1 1 6 247 forceArc forceArc puls AlMg...

Страница 75: ...rc forceArc puls CrNi 18 8 1 4370 Ar 97 5 CO2 2 5 M12 1 2 309 forceArc forceArc puls CrNi 18 8 1 4370 Ar 97 5 CO2 2 5 M12 1 6 311 forceArc forceArc puls CrNi 19 12 3 1 4430 Ar 97 5 CO2 2 5 M12 1 0 312...

Страница 76: ...1 0 360 wiredArc wiredArc puls G3Si1 G4Si1 Ar 82 CO2 18 M21 1 2 367 wiredArc wiredArc puls CrNi 19 9 1 4316 Ar 97 5 CO2 2 5 M12 1 0 368 wiredArc wiredArc puls CrNi 19 9 1 4316 Ar 97 5 CO2 2 5 M12 1 2...

Страница 77: ...1 MIG MAG welding Name Display Setting range Code Standard ex works Unit Min Max Voltage correction 0 V 9 9 9 9 Wire feed speed absolute main program PA m min 0 00 20 0 Gas nominal value option GFE 8...

Страница 78: ...Appendix Searching for a dealer 78 099 5TLPXQ EW501 29 01 2021 7 3 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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