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For your safety

Part of the complete documentation

099-00T400-EW501

21.10.2016

2.2

Part of the complete documentation

These operating instructions are 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 2-1

Item Documentation

A.1

Options conversion instructions

A.2

Power source

A.3

Cooling unit, voltage converter, tool box etc.

A.4

Transport cart

A.5

Welding torch

A.6

Remote control

A.7

Control

Complete documentation

Содержание T 4.00 - AC/DC Comfort 2.0

Страница 1: ...ions EN Control T 4 00 AC DC Comfort 2 0 099 00T400 EW501 Observe additional system documents 21 10 2016 Register now and benefit Jetzt Registrieren und Profitieren www ewm group com For details visit...

Страница 2: ...ervice department on 49 2680 181 0 A list of authorised sales partners can be found at www ewm group com Liability relating to the operation of this equipment is restricted solely to the function of t...

Страница 3: ...4 1 3 Tungsten balling function 18 4 1 4 AC balance optimise cleaning effect and penetration characteristics 19 4 1 5 AC amplitude balance 20 4 1 6 Arc ignition 21 4 1 6 1 HF ignition 21 4 1 6 2 Lifta...

Страница 4: ...re welding 61 4 3 1 Configuring the welding machine for mechanical arc fusion welding 61 4 3 1 1 Selecting a welding task by means of the JOB list 61 4 3 1 2 Select wire speed operating mode KORREKTUR...

Страница 5: ...erved to prevent serious and even fatal injuries Safety notes include the WARNING keyword in the heading with a general warning symbol The hazard is also highlighted using a symbol in the page margin...

Страница 6: ...tap tip Switch off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Correct Numerical value adjustable Menu entry Signal light lights up in green Navigating the menu Signal l...

Страница 7: ...l 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 syste...

Страница 8: ...description purposes the machine control has been divided into three sections A B C to ensure maximum clarity The setting range for the parameter values are summarised in the parameter overview sectio...

Страница 9: ...hapter Press button for long interval to put machine into power saving mode see 4 4 chapter Activate one of the operating elements to reactivate 4 Pulsing push button see 4 1 10 chapter Automated puls...

Страница 10: ...ssure is lost in the coolant circuit Check coolant level and ensure that coolant circuit is leak tight 13 VRD Voltage reduction device VRD signal light The VRD signal light is illuminated when the vol...

Страница 11: ...nce JOBs 0 7 AC balance JOBs 1 7 pulse balance AC amplitude balance JOBs 0 7 5 Electrode diameter signal light Ignition optimisation TIG tungsten balling basic setting 6 Gas post flow time 7 AMP Signa...

Страница 12: ...elding process Switch activArc Correct the activArc characteristic see 4 1 20 chapter 15 Signal light two colour Green AC frequency TIG pulse frequency MMA Red Pulse frequency TIG kHz pulsing 3 1 3 Co...

Страница 13: ...the settings are then changed e g welding current the display will switch to the relevant nominal values possible not possible The parameters that can be set in the function sequence of the machine co...

Страница 14: ...navigate to the required parameter Press again to apply the selected parameter as the setting corresponding signal light flashes Turn the button to set the parameter value The welding parameter settin...

Страница 15: ...ing gas flows continuously until the push button is pressed again If the shielding gas setting is too low or too high this can introduce air to the weld pool and may cause pores to form Adjust the shi...

Страница 16: ...also be set to meet individual requirements e g for thin panels a smaller diameter is recommended to reduce the ignition energy The electrode diameter setting determines the minimum current limit whic...

Страница 17: ...g task is set as described previously The three rotary knobs for AC frequency AC balance and the tungsten electrode diameter are exceptions These settings are made in the operation sequence signal lig...

Страница 18: ...et electrode diameter affects the current for tungsten balling and consequently also the ball size Press the tungsten balling push button to activate the function If required this current can be adjus...

Страница 19: ...ffect At the same time tungsten balling occurs at the tip of the tungsten electrode The size of this balled end depends on the length of the positive phase Please note that an excessively big balled e...

Страница 20: ...or positive phase and negative phase are set for AC amplitude balance The balance changes in terms of the current amplitude Figure 4 5 Increasing the current amplitude in the positive half wave facili...

Страница 21: ...ectrode tip onto the workpiece and press the torch trigger liftarc current flowing regardless of the main current set b Incline the torch over the torch gas nozzle to produce a gap of approx 2 3 mm be...

Страница 22: ...urrent t Time Gas pre flow Ignition current Up slope time Spot time AMP Main current minimum to maximum current AMP Secondary current Pulse time Pulse pause time Pulse current Pulsed TIG welding Slope...

Страница 23: ...reases to the secondary current AMP in the set slope time If torch trigger 2 is released the welding current increases again to the main current AMP in the set slope time The parameters and can be set...

Страница 24: ...rater current within the set down slope time 4th cycle Release torch trigger 1 arc is extinguished Set gas post flow time runs Ending the welding process immediately without a down slope or end crater...

Страница 25: ...welded on top of one another As this is a one sided process it is also possible to weld metal sheets onto tubular sections such as round or square pipes In arc spot welding the arc melts through the u...

Страница 26: ...pulses jump from the electrode to the workpiece The arc ignites The welding current flows and immediately assumes the value of the ignition current HF switches off The welding current ramps up to the...

Страница 27: ...to be reactivated for every arc ignition by pressing the torch trigger Permanent process activation The welding process is activated by pressing the torch trigger once The following arc ignitions are...

Страница 28: ...e workpiece Incline the welding torch over the torch gas nozzle until there is a gap of approx 2 3 mm between the electrode tip and the workpiece Shielding gas flows during the set gas pre flow time T...

Страница 29: ...lding current ramps up to the main current AMP in the selected up slope time Pressing torch trigger 1 starts the slope from main current AMP to secondary current AMP Releasing the torch trigger starts...

Страница 30: ...g in the molten pool and the tungsten inclusions are reduced This is particularly useful in tacking and in spot welding Selection EXIT 4s Figure 4 15 Setting Parameter setting The activArc parameter c...

Страница 31: ...DC Metallurgical pulsing TIG DC AC special TIG AC 4 1 10 1 Automated pulses The automated pulses are used with tacking and spot welding of workpieces in particular An oscillation in the molten pool is...

Страница 32: ...ditional switching back and forth between the main current AMP pulse current and the secondary current AMP pulse pause current at the set times Pulse and pause times and the pulse edges and are entere...

Страница 33: ...ng 099 00T400 EW501 21 10 2016 33 Selection Figure 4 19 Pulse time setting EXIT 4s Figure 4 20 Pulse pause setting EXIT 4s Figure 4 21 Pulse edge setting The and pulse edges can be set in the Expert m...

Страница 34: ...ue pulse welding means that the system switches between two currents periodically an average current value AMP a pulse current Ipuls a balance and a frequency having been defined first The predefined...

Страница 35: ...ulsing uses the plasma force arc force occurring at high currents which allows you to achieve a constricted arc with concentrated heat input Unlike thermal pulsing no times are set a frequency and the...

Страница 36: ...Welding procedure TIG welding 36 099 00T400 EW501 21 10 2016 Balance setting EXIT 4s Figure 4 26 Frequency setting EXIT 4s Figure 4 27...

Страница 37: ...TIG welding 099 00T400 EW501 21 10 2016 37 4 1 10 5 AC special Is e g used to join metal sheets of different thickness Figure 4 28 Figure 4 29 The and pulse edges can be set in the Expert menu TIG se...

Страница 38: ...apping function Swiftly tap the torch trigger to change the function The torch mode set determines the operating mode of the tapping function 4 1 12 Torch mode and up down speed setting Modes 1 to 6 a...

Страница 39: ...on Functions mode Operating elements Welding current On Off 1 factory set Secondary current Latched mode Standard torch with two torch triggers Diagram Operating elements Explanation of symbols BRT1 t...

Страница 40: ...symbols BRT 1 torch trigger 1 BRT 2 torch trigger 2 Functions mode Operating elements Welding current On Off 1 factory set Secondary current Secondary current tapping mode latched mode Welding curren...

Страница 41: ...Operating elements Welding current on off 1 factory set Secondary current tapping mode latched mode Increase welding current infinite adjustment up function Reduce welding current infinite adjustment...

Страница 42: ...off 1 factory set Secondary current Secondary current tapping mode latched mode Increase welding current infinite adjustment up function Reduce welding current infinite adjustment down function Weldin...

Страница 43: ...1 Functions Mode Operating elements Welding current On Off 3 Secondary current tapping mode Increase welding current infinite adjustment Reduce welding current infinite adjustment Potentiometer torch...

Страница 44: ...ead the safety instructions in this manual Observe the accident prevention regulations and any regional regulations Inform persons in the working area that they must comply with the regulations Test B...

Страница 45: ...ropriate Welding current on off 4 TT 1 Secondary current TT 2 Secondary current tapping function TT 1 tapping Raise welding current in stages setting the first increment TT 3 Decrease welding current...

Страница 46: ...ant torch trigger the current can be roughly adjusted Holding the torch trigger will cause an infinite adjustment of the welding current This function is only available when using up down torches in m...

Страница 47: ...ng selection Alternating current waveforms Rectangular ex works Trapezoidal Sine AC welding with rectangular current waveform ex works Highest energy input Alternating current welding with trapezoidal...

Страница 48: ...to weld Within the preset range the main current can be set by adjusting the pressure on the pedal Linear responsiveness ex works Welding current changes linearly Figure 4 33 Logarithmic responsivene...

Страница 49: ...Figure 4 35 Symbol Meaning Actuate foot operated remote control start welding process Operate foot operated remote control set welding current according to application Release foot operated remote co...

Страница 50: ...ol adjusts or sets the AC frequency in relation to the set main current The lower the welding current the higher the frequency and vice versa This ensures a concentrated directionally stable arc is ac...

Страница 51: ...ck aluminium materials in the PF position This ensures that with alternating currents the positive and negative pole phases are present on both power sources simultaneously thus avoiding the arcs nega...

Страница 52: ...AVIGATION Navigate the menu Parameters are selected by turning the main control button or pressing the Parameter selection left right push button Change parameters by pressing parameter selection and...

Страница 53: ...on wire feeding behaviour when using pulsed TIG welding Wire feeding can be disabled during pulse pauses not the case for automated pulsing or kHz pulsing Function disabled Function enabled ex works F...

Страница 54: ...torch or the intermediate hose package AW has been changed The resistance value of the cables can be set directly or can be aligned by the power source In the delivery state the cable resistance is se...

Страница 55: ...ure press the welding torch with the collet against a clean purged location on the workpiece and then press the torch trigger for approx 2 seconds A short circuit current will flow briefly which is us...

Страница 56: ...change the basic parameters when no welding current is flowing and any possible access control is disabled see 4 5 chapter The welding task is selected using the buttons on the machine control on the...

Страница 57: ...er hot start current After selecting the stick electrode the arc ignites with the hot start current for the preset hot start time and then reverts to the main current AMP The parameter values for hot...

Страница 58: ...ectrode sticks in spite of the Arcforce device the machine automatically switches over to the minimum current within about 1 second to prevent the electrode from overheating Check the welding current...

Страница 59: ...nt IPP a balance and a frequency having been defined first Figure 4 47 AMP main current e g 100 A Ipuls pulse current x AMP e g 140 x 100 A 140 A IPP pulse pause current 1 200 of AMP Tpuls duration of...

Страница 60: ...MP a pulse current Ipuls a balance and a frequency having been defined first The predefined ampere current average value is decisive the pulse current Ipuls is defined by the parameter as a percentage...

Страница 61: ...apter wire feeding will not take place In order to carry out the chosen welding task the wire feed unit must be switched to the MANUELL operating mode 4 3 1 2 Select wire speed operating mode KORREKTU...

Страница 62: ...g current on or off Torch trigger 1 BRT 1 switches the wire feed on or off The operator can choose between three operating modes see following function sequences Figure 4 51 4 3 2 1 Explanation of sym...

Страница 63: ...cted up slope time 1st cycle wire Press torch trigger 1 BRT 1 Wire electrode is advanced 2nd cycle wire Release BRT 1 Wire electrode advance stops 3rd cycle current Press BRT 2 The main current ramps...

Страница 64: ...ctrode is fed corresponding to the welding current until the welding process ends 4 3 2 4 Latched mode Figure 4 54 This operating mode differs from non latched operation in the following ways Wire fee...

Страница 65: ...ter to access block enabled The access block activation is indicated by the Access block active signal light see 3 1 1 chapter Disabling access block Enter the access code for the access block Select...

Страница 66: ...1 21 10 2016 ENTER l 0 NAVIGATION A A A A A B B B B B B B B B B A A A A A A A A A A A A A A A A A A B B B B B B B B B B B B B B B A A A A A A A A A A A A B B B B B B B B B B A A A B A A A A B B B A A...

Страница 67: ...Welding current setting absolute Welding current setting as a percentage of the main current Non latched operation version C see 4 1 7 6 chapter Function enabled Function disabled ex works Current di...

Страница 68: ...the left stop ex works Tungsten balling old variant Function enabled Function disabled ex works Welding current polarity switching polarity switching at the RT PWS 1 19POL remote control ex works pola...

Страница 69: ...t static tube and the welding process monitoring phase Function disabled ex works Monitoring during the welding process Gas sensor between gas valve and welding torch with pilot static tube Monitoring...

Страница 70: ...enu Complete reset of all values and settings Resetting is performed when exiting the menu Software version query example 07 system bus ID 03c0 version number System bus ID and version number are sepa...

Страница 71: ...depends on the machine version interfaces functions In case of multiple warnings these are displayed in sequence Document machine warning and inform service personnel if required Warning code Possibl...

Страница 72: ...ge Switch machine off and on again inform the service department if the error continues Err 10 PE error Err 11 FastStop position Edge Acknowledge error signal 0 to 1 via robot interface if available E...

Страница 73: ...emperature The excess temperature of the high frequency blocking inductor has triggered Allow equipment to cool down Adjust processing cycle times if necessary Reset error via robot interface reset er...

Страница 74: ...ters that are stored will be replaced by the factory settings To reset the welding parameters or machine settings to the factory settings select parameter in the service menu see 4 7 chapter 5 4 Displ...

Страница 75: ...P 50 1 200 of main current AMP Pulse pause time s 0 01 0 00 20 0 Slope time s 0 00 0 00 20 0 Time from main current AMP to secondary current AMP Down slope time s 1 0 0 0 20 0 End current AMP 20 1 200...

Страница 76: ...er MMA Display Setting range Comment Code Unit Standard Min Max Main current A 5 300 Hot start current 120 1 200 of main current AMP parameter to setting Hot start time s 0 5 0 0 10 0 Arcforce 0 40 40...

Страница 77: ...Appendix B Overview of EWM branches 099 00T400 EW501 21 10 2016 77 7 Appendix B 7 1 Overview of EWM branches...

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