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Machine control – Operating elements

Overview of control sections

099-00T500-EW501

2.9.2022

Item Symbol Description

Signal light for status display

After each completed welding process, the last values used for welding current and vol-

tage are shown in the displays and the signal light is on.

Access control active signal light

Signal light is on when access control is active on the machine con-

trol

> see 5.8 chapter

Without function in this machine version.

Signal light welding voltage

Illuminates when the welding voltage is displayed in volts.

Without function in this machine version.

Automatic AC frequency

> see 5.2.3.5 chapter

Without function in this machine version.

Signal light - display value in Inches per minute

Signal light - display value in metres per minute

VRD Voltage reduction device (VRD) signal light

> see 5.9 chapter

Содержание T5.00

Страница 1: ...Operating instructions EN Control T5 00 AC DC Comfort 3 0 099 00T500 EW501 Observe additional system documents 2 9 2022...

Страница 2: ...to the operation of this equipment is restricted solely to the function of the equipment No other form of liability regardless of type shall be accepted This exclusion of liability shall be deemed ac...

Страница 3: ...er setting in theoperationsequence 22 4 3 4 Setting advanced welding parameters Expert menu 23 4 3 5 Changing basic settings machineconfiguration menu 23 4 3 6 Lock function 23 5 Functional characteri...

Страница 4: ...matic AC frequency 56 5 3 7 Pulse welding 57 5 3 7 1 Averagevaluepulse welding 57 5 4 Arc length restriction USP 57 5 5 JOB favourites 58 5 5 1 Saving current settings to Favourites 58 5 5 2 Loading s...

Страница 5: ...Contents Notes on using these operating instructions 099 00T500 EW501 2 9 2022 5 8 2 Searching for adealer 81...

Страница 6: ...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 oper...

Страница 7: ...on machine Press and hold Incorrect Invalid Switch Correct Valid Turn Input Numerical value adjustable Navigation Signal light lights up in green Output Signal light flashes green Time representation...

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: ...emperatures 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 excessive...

Страница 10: ...ified 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 user must...

Страница 11: ...lacement 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: ...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 power...

Страница 13: ...plate Hazards may arise for persons animals and material objects if the equipment is not used correctly No liability is accepted for any damages arising from improper usage The equipment must only be...

Страница 14: ...this marking can be used for welding in an environment with increased electrical hazard e g boilers For this purpose appropriate national or international regulations must be followed The power sourc...

Страница 15: ...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...

Страница 16: ...escription 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 section...

Страница 17: ...ion protection against accidental adjustment see 4 3 6chapter 2 push button JOB Favourites see 5 5 chapter Pressing the push button briefly Loading Favourites Press and hold the push button 2 s Saving...

Страница 18: ...sing push button see 5 2 8 chapter Average value pulsing Thermal pulsing Automated pulsing AC special 7 Push button for welding current polarity tungsten balling DC welding with either negative or pos...

Страница 19: ...millimetres 7 Signal light display value in inch 8 Excess temperature signal light In case of excess temperature temperature monitors de activate the power unit and the excess temperature control lamp...

Страница 20: ...is active on the machine con trol see 5 8 chapter 15 Without function in this machine version 16 Signal light welding voltage Illuminates when the welding voltage is displayed in volts 17 Without fun...

Страница 21: ...n TIG 7 JOB Signal light for welding task JOB 8 tst Signal light for start current time 9 Signal light activArc see 5 2 6 chapter 10 Signal light for balance 11 t1 Signal light for pulse time 12 Signa...

Страница 22: ...ans that the previously selected settings are accepted if necessary indicated by signal lights and the nominal value of the current A is shown in the welding data display on the left The welding data...

Страница 23: ...hold the click wheel 2 s Select the appropriate parameter menu item by turning navigating and pressing confirming the click wheel 4 3 5 Changing basic settings machine configuration menu The basic we...

Страница 24: ...mm corresponds to the gas flow in l min Helium rich gas mixtures require a higher gas volume The table below can be used to correct the gas volume calculated where necessary Shielding gas Factor 75 A...

Страница 25: ...eter a minimum current limit is set that in turn affects the start main and secondary currents Minimum current limits prevent an unstable arc at impermissibly low currents If necessary the minimum cur...

Страница 26: ...arameters ignition current and ignition time The ignition time is set absolutely in milliseconds The setting of the ignition current differs in the setting variants and In the variant the ignition cur...

Страница 27: ...ing task as described previously With the JOB manager see 5 6 chapter welding tasks canbe copied to any preset or reset to thefac tory settings The desired JOB can also be assigned to a quick access b...

Страница 28: ...ode Pulse function 1 80A Non latched Pulses on 2 70A latched Pulses off The operating mode cannot be changed during the welding process If welding is started with program 1 non latched operating mode...

Страница 29: ...electrode tip melts into a ball the so called balled end due to the high thermal effect of thepositive half wave The size of the balled end depends on the length balance setting see 5 2 3 3 chapter an...

Страница 30: ...and thus the balled end size The function is enabled by pressing thepush button tungsten balling and indicated by the flashing of the corresponding signal light If required this current can be adjust...

Страница 31: ...setting of the balance is 65 and always refers to the negative half wave The positive half wave is adjusted accordingly negative half wave 65 positive half wave 35 Figure 5 9 5 2 3 4 AC amplitude bal...

Страница 32: ...hine control takes over the regulation or setting of the alternating current frequency depending on the set main current The lower the welding current the higher the frequency and vice versa This achi...

Страница 33: ...g task Automatic modeis the preferred choice for almost every ap plication Manual mode 1 100 If the result in automatic mode is not satisfactory in rare cases the commutation optimisation can be adjus...

Страница 34: ...nding on the operat ing mode set to the ignition or main current set c Lift off the torch and swivel to the normal position Ending the welding process Release the torch trigger or press and release de...

Страница 35: ...in current minimum to maximum current AMP Secondary current Pulse time Pulse pause time Pulse current Latched operating mode Slope time from main current AMP to secondary current AMP TIG thermal pulsi...

Страница 36: ...the HF ignition shuts down The welding current increases in the up slope time to the main current 2nd cycle Release torch trigger 1 The main current drops during the down slope time to theend current...

Страница 37: ...g gas is shut down Alternative welding start tap start The tap start function must be switched on before using it With the alternative welding start the du ration of the first and second cycle is only...

Страница 38: ...es jump from the electrode to the workpiece The arc ignites The welding current flows and immediately assumes the value of the start current HF switches off The welding current ramps up to the main cu...

Страница 39: ...he torch trigger Process activation is automatically terminated after 30 s of inactivity Permanent process activation The welding process is activated by pressing the torch trigger once The following...

Страница 40: ...Press and release the torch trigger tap to reactivate the welding process only for separate process activation Touching the welding torch with the tungsten electrode tip against the workpiece again wi...

Страница 41: ...events the tungsten electrodesticking in the molten pool and the tungsten inclusions are reduced Selection 4s Figure 5 23 Setting Parameter setting The activArc parameter control can be adjusted speci...

Страница 42: ...lace periodically between two currents whereby an average current value AMP a pulse current Ipuls pulse balance and pulse frequency must be spe cified The set averagecurrent value in ampere is decisiv...

Страница 43: ...onds on the control The and pulse edges can be set in the Expert menu TIG see 5 2 12 chapter Figure 5 26 Setting the pulse and pulse pause time 4s Figure 5 27 5 2 9 2 Automated pulses The automated pu...

Страница 44: ...al sheets of different thickness Pulse time setting Figure 5 28 The and pulse edges can be set in the Expert menu TIG see 5 2 12 chapter 5 2 9 4 Pulsing in an upslope downslope The pulse function can...

Страница 45: ...ase the value DOWN Torch trigger DOWN decrease the value The torch modes are set using the torch configuration parameters in the machine configuration menu torch mode see 5 11 chapter Only the modes l...

Страница 46: ...ent in steps current jump UP Decrease welding current in steps current jump DOWN Welding torch with two torch triggers and up down push buttons Figure 5 33 Function Operation Mode Welding current On O...

Страница 47: ...ondary current in latched operation Secondary current in latched operation BRT 2 Increase welding current in steps current jump UP Decrease welding current in steps current jump DOWN Switching between...

Страница 48: ...separately for each torch mode for the start of welding with parame ter and for the end of welding with parameter If parameter is activated there is no need to tap the secondary current 5 2 10 3 Up do...

Страница 49: ...e remote control pe dal very quickly down by approx 50 of the pedal travel Start ramp is switched on The welding current increases in a linear slow ramp to approx 100 A Start ramp is switched off The...

Страница 50: ...e between linear and logarithmic responsiveness The logarithmic setting is particularly suitable for welding with low current e g for thin panels as the logarithmic responsiveness enables better contr...

Страница 51: ...Slope time main current to secondary current Slope time secondary current to main current Amplitude balance see 5 2 3 4 chapter Commutation optimisation AC see 5 2 3 6 chapter Parameter activArc see 5...

Страница 52: ...an accessory component suchas the welding torch or the intermediate hose package AW has been chan ged The resistance value of the cables can beset directly or can be aligned by the power source In the...

Страница 53: ...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 used to determine and display the cable resist...

Страница 54: ...he selection process always has the same sequence Signal lights LED will show the selected combination Cel Cel Figure 5 39 5 3 2 Hotstart The function hot start ensures a secure igniting of the arc an...

Страница 55: ...trode types at low current strengths with a short arc in particular 4s Arcforce Arcforce Figure 5 42 5 3 4 Antistick The Antistick feature prevents the electrode from annealing Should the electrode st...

Страница 56: ...ency By turning to the left the parameter value is reduced until the parameter AC frequency automatic is shown in the display The signal light comes on when the function is enabled The machine control...

Страница 57: ...s a percentage of the current average value AMP The pulse pausecurrent IPP requires no setting This value is calculated by the machine control so that the welding current average value AMP is maintain...

Страница 58: ...he push button 2 s Saving as a Favourite Press and hold the push button 12 s Deleting a Favourite 2 Signal light of Favourite status Signal light is green Favourite loaded settings of the Favourite an...

Страница 59: ...er 2 seconds the signal light of thefavourite status turns green after another 5 s the signal light starts flashing red after another 5 s the signal light goes out Release the favourite memory push bu...

Страница 60: ...ntrol can be locked to secure it against unauthorised or unintentional adjustment The access block has the following effect The parameters and their settings in the machine configuration menu Expert m...

Страница 61: ...cification This function enables aligning the machine to the mains connection fusing This may counteract frequent tripping of the mains fuse The maximum input power of the machine is limited with an e...

Страница 62: ...n factory setting hard ignition Ignition pulse dynamics Function enabled factory setting Function disabled Minimum current limit TIG see 5 1 2 chapter Depending on the set tungsten electrode diameter...

Страница 63: ...nction enabled ex works Function disabled Spot time setting see 5 2 5 5 chapter Short spot time setting range 5 ms to 999 ms increments of 1 ms ex works Long spot time setting range 0 01 s to 20 0 s i...

Страница 64: ...mps up to the preset main current factory setting The welding current jumps immediately to the preset main current Responsiveness see 5 2 11 2 chapter Linear responsiveness Logarithmic responsiveness...

Страница 65: ...ching via interface for automated welding Non latched Special non latched Error output relay 3 Potential free relay contact Relay contact for error message is open factory setting Relay contact for er...

Страница 66: ...n accidental selection of polarity DC and the associated destruction of the tungsten electrode factory setting Polarity switching to DC is possible Polarity switching is disabled factory setting Gas m...

Страница 67: ...ety precautions Follow the maintenance instructions If any of the test requirements below are not met the unit must not be put back into opera tion until it has been repaired and tested again Repair a...

Страница 68: ...em separate from unsorted municipal waste The public waste management utilities communities have created collection points at which used equipment from private households can be disposed of free of ch...

Страница 69: ...coolant level and top up if necessary 4 Shielding gas Check shielding gas supply 5 Coolant flow Check min flow rate 2 6 Wire reserve Only a small amount of wire is left on the spool 7 CAN bus failure...

Страница 70: ...rent detected onwire feed motor 34 JOB unknown JOB selection was not carried out because the JOB number is unknown 35 Excess current on the wire feed motor slave Excess current detected onwire feed mo...

Страница 71: ...eliminated B The error message can be reset by pressing a push button All other error messages can only be reset by switching the machine off and on again Error 3 Tacho error Category A B Fault in th...

Страница 72: ...ng Connect the coolant feed and return with a hose bridge Error 8 Shielding gas error Category A B No shielding gas Check the shielding gas supply The pre pressure is too low Remove kinks in the hose...

Страница 73: ...place Air inlet or outlet is blocked Check the air inlet and outlet Short circuit on welding torch Check the welding torch Request service Error 17 Cold wire error Category B Fault in the wire feeder...

Страница 74: ...he switched on machine to cool Fan is blocked dirty or defective Check clean or replace the fan Air inlet or outlet is blocked Check the air inlet and outlet Error 23 Excess temperature of the HF chok...

Страница 75: ...equest service Error 37 Electronics error The power source is overheating Allow the switched on machine to cool Fan is blocked dirty or defective Check fan and clean or replace Air inlet or outlet is...

Страница 76: ...n activated internally configurable Deactivate the emergency stop circuit Error 52 No wire feeder After switching on the automated system no wire feeder DV was detected Check or connect the control ca...

Страница 77: ...achine from the system Request service Error 61 Welding monitoring The actual value of a welding parameter is outside thespecified tolerance range Maintain the tolerance ranges Adjust the welding para...

Страница 78: ...time 0 01 s 0 01 20 0 Slope time time from to 0 00 s 0 00 20 0 Main current power source dependent A Slope time time from to 0 00 s 0 00 20 0 Slope time time from to 0 00 s 0 00 20 0 Secondary curren...

Страница 79: ...e value pulsing DC 2 00 Hz 0 10 20000 Pulse frequency average value pulsing AC 2 00 Hz 0 10 5 00 8 1 1 2 AC parameters Name Display Setting range Code Standard Unit min max Balance 65 40 90 Frequency...

Страница 80: ...00 Balance 60 40 90 8 1 3 Global parameters Name Display Setting range Code Standard Unit min max Standby 20 m 5 60 Re ignite after arc interruption Job s 0 1 5 Torch mode 1 1 6 Up down speed 10 1 100...

Страница 81: ...Appendix Searching for a dealer 099 00T500 EW501 2 9 2022 81 8 2 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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