EWM Phoenix 355 Progress puls MM TKM, alpha Q 330 Progress puls HP MM TKM Operating Instructions Manual

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Operating instructions

Welding machine

Phoenix 355 Progress puls MM TKM

099-005403-EW501

18.08.2016

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General instructions

WARNING

Read the operating instructions! The operating instructions provide an introduction to the safe use of the products.

• Read and observe the operating instructions for all system components, especially the safety instructions and warning notices!

• Observe the accident prevention regulations and any regional regulations!

• The operating instructions must be kept at the location where the machine is operated.

• Safety and warning labels on the machine indicate any possible risks.

Keep these labels clean and legible at all times.

• The machine has been constructed to state-of-the-art standards in line with any applicable regulations and industrial standards. Only trained personnel may operate, service and repair the machine.

• Technical changes due to further development in machine technology may lead to a differing welding behaviour.

In the event of queries on installation, commissioning, operation or special conditions at the installation site, or on usage, please contact your sales partner or our customer service 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 the equipment. 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 monitor whether or not these instructions or the conditions and methods are observed during installation, operation, usage and maintenance of the equipment.

An incorrectly performed installation can result in material damage and injure persons as a result. For this reason, we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation, improper operation or incorrect usage and maintenance or any actions connected to this in any way.

Germany

The copyright to this document remains the property of the manufacturer. Copying, including extracts, only permitted with written approval. The content of this document has been prepared and reviewed with all reasonable care. The information

provided is subject to change; errors excepted.

Contents

Notes on the use of these operating instructions

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1 Contents

1 Contents .................................................................................................................................................. 3

2 Safety instructions ................................................................................................................................. 6

2.1 Notes on the use of these operating instructions .......................................................................... 6

2.2 Explanation of icons ....................................................................................................................... 7

2.3 Safety instructions .......................................................................................................................... 8

2.4 Transport and installation ............................................................................................................ 12

3 Intended use ......................................................................................................................................... 13

3.1 Documents which also apply ....................................................................................................... 13

3.1.1 Warranty ....................................................................................................................... 13

3.1.2 Declaration of Conformity ............................................................................................. 13

3.1.3 Welding in environments with increased electrical hazards ......................................... 13

3.1.4 Service documents (spare parts and circuit diagrams) ................................................ 13

3.1.5 Calibration/Validation ................................................................................................... 13

4 Machine description – quick overview .............................................................................................. 14

4.1 Front view .................................................................................................................................... 14

4.2 Rear view ..................................................................................................................................... 16

4.2.1 Operating elements in the machine .............................................................................. 18

4.3 Machine control – Operating elements ........................................................................................ 19

4.3.1 Function sequence ....................................................................................................... 21

5 Design and function ............................................................................................................................. 23

5.1 Transport and installation ............................................................................................................ 23

5.1.1 Ambient conditions ....................................................................................................... 23

5.1.2 Machine cooling ............................................................................................................ 24

5.1.3 Workpiece lead, general ............................................................................................... 24

5.1.4 Protective flap, welding machine control ...................................................................... 24

5.1.5 Welding torch holder .................................................................................................... 25

5.1.6 Welding torch cooling system ....................................................................................... 26

5.1.6.1 Cooling module connection ........................................................................... 26

5.1.7 Notes on the installation of welding current leads ........................................................ 27

5.1.7.1 Stray welding currents................................................................................... 28

5.1.8 Mains connection .......................................................................................................... 29

5.1.8.1 Mains configuration ....................................................................................... 29

5.1.9 Shielding gas supply (shielding gas cylinder for welding machine) ............................. 30

5.1.9.1 Pressure regulator connection ...................................................................... 30

5.1.9.2 Shielding gas hose connection ..................................................................... 31

5.1.9.3 Gas test – setting the shielding gas volume ................................................. 32

5.2 Welding data display .................................................................................................................... 33

5.3 MIG/MAG welding ........................................................................................................................ 34

5.3.1 Welding torch and workpiece line connection .............................................................. 34

5.3.2 Welding torch and workpiece line connection .............................................................. 35

5.3.3 Wire feed ...................................................................................................................... 37

5.3.3.1 Open the protective flap of the wire feeder ................................................... 37

5.3.3.2 Inserting the wire spool ................................................................................. 38

5.3.3.3 Changing the wire feed rollers ...................................................................... 39

5.3.3.4 Inching the wire electrode ............................................................................. 41

5.3.3.5 Spool brake setting ....................................................................................... 42

5.3.4 Definition of MIG/MAG welding tasks ........................................................................... 43

5.3.5 Welding task selection .................................................................................................. 43

5.3.5.1 Basic welding parameters ............................................................................. 43

5.3.5.2 Choke effect / dynamics ................................................................................ 44

5.3.5.3 superPuls ...................................................................................................... 45

5.3.5.4 Burn-back ...................................................................................................... 46

5.3.6 MIG/MAG operating point ............................................................................................. 47

5.3.6.1 Selecting the display unit .............................................................................. 47

5.3.6.2 Operating point setting using material thickness .......................................... 48

5.3.6.3 Arc length correction setting ......................................................................... 48

Contents

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5.3.6.4 Accessory components for operating point setting ....................................... 48

5.3.7 forceArc / forceArc puls ................................................................................................ 49

5.3.8 rootArc/rootArc puls ...................................................................................................... 50

5.3.9 MIG/MAG functional sequences / operating modes ..................................................... 51

5.3.9.1 Explanation of signs and functions ................................................................ 51

5.3.10 Conventional MIG/MAG Welding (GMAW non synergic) ............................................. 64

5.3.10.1 Setting the operating point (welding output).................................................. 64

5.3.11 MIG/MAG program sequence ("Program steps" mode) ............................................... 65

5.3.11.1 Selection of the program sequence parameter ............................................. 65

5.3.11.2 MIG/MAG overview of parameters ................................................................ 66

5.3.11.3 Example, tack welding (non-latched) ............................................................ 67

5.3.11.4 Example, aluminium tack welding (non-latched special) .............................. 67

5.3.11.5 Example, aluminium welding (latched special) ............................................. 68

5.3.11.6 Example, visible seams (latched super pulse) .............................................. 69

5.3.12 Main program A mode .................................................................................................. 70

5.3.12.1 Selecting parameters (program A) ................................................................ 72

5.3.13 MIG/MAG automatic cut-out ......................................................................................... 72

5.3.14 Standard MIG/MAG torch ............................................................................................. 73

5.3.15 MIG/MAG special-torches............................................................................................. 73

5.3.15.1 Program- and Up / down operation ............................................................... 73

5.3.15.2 Switching between Push/Pull and intermediate drive ................................... 73

5.3.16 Expert menu (MIG/MAG) .............................................................................................. 74

5.3.16.1 Selection ........................................................................................................ 74

5.4 TIG welding .................................................................................................................................. 76

5.4.1 Welding torch and workpiece line connection .............................................................. 76

5.4.2 Welding task selection .................................................................................................. 77

5.4.3 Welding current setting ................................................................................................. 77

5.4.4 TIG arc ignition ............................................................................................................. 77

5.4.4.1 Liftarc ............................................................................................................. 77

5.4.5 Function sequences/operating modes .......................................................................... 78

5.4.5.1 Explanation of signs and functions ................................................................ 78

5.4.6 TIG automatic cut-out ................................................................................................... 81

5.4.7 TIG program sequence ("Program steps" mode) ......................................................... 82

5.5 MMA welding ................................................................................................................................ 83

5.5.1 Connecting the electrode holder and workpiece lead .................................................. 83

5.5.2 Welding task selection .................................................................................................. 84

5.5.3 Arcforce......................................................................................................................... 84

5.5.4 Hotstart ......................................................................................................................... 85

5.5.5 Antistick......................................................................................................................... 85

5.5.6 Parameter overview ...................................................................................................... 85

5.6 Remote control ............................................................................................................................. 86

5.7 Interfaces for automation ............................................................................................................. 86

5.7.1 Automation interface ..................................................................................................... 87

5.7.2 Remote control connection socket, 19-pole ................................................................. 88

5.7.3 RINT X12 robot interface .............................................................................................. 89

5.7.4 BUSINT X11 Industrial bus interface ............................................................................ 89

5.8 PC interface ................................................................................................................................. 89

5.9 Access control .............................................................................................................................. 90

5.10 Special parameters (advanced settings) ...................................................................................... 90

5.10.1 Selecting, changing and saving parameters................................................................. 91

5.10.1.1 Reset to factory settings ................................................................................ 93

5.10.1.2 Special parameters in detail .......................................................................... 94

5.11 Machine configuration menu ...................................................................................................... 103

5.11.1 Selecting, changing and saving parameters............................................................... 103

5.11.2 Aligning the cable resistance ...................................................................................... 105

5.11.3 Power-saving mode (Standby) ................................................................................... 106

6 Maintenance, care and disposal ....................................................................................................... 107

6.1 General....................................................................................................................................... 107

6.2 Cleaning ..................................................................................................................................... 107

6.3 Maintenance work, intervals ...................................................................................................... 108

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6.3.1 Daily maintenance tasks ............................................................................................ 108

6.3.1.1 Visual inspection ......................................................................................... 108

6.3.1.2 Functional test ............................................................................................. 108

6.3.2 Monthly maintenance tasks ........................................................................................ 108

6.3.2.1 Visual inspection ......................................................................................... 108

6.3.2.2 Functional test ............................................................................................. 108

6.3.3 Annual test (inspection and testing during operation) ................................................ 109

6.4 Disposing of equipment ............................................................................................................. 109

6.4.1 Manufacturer's declaration to the end user ................................................................ 109

6.5 Meeting the requirements of RoHS ........................................................................................... 109

7 Rectifying faults ................................................................................................................................. 110

7.1 Checklist for rectifying faults ...................................................................................................... 110

7.2 Error messages (power source) ................................................................................................ 111

7.3 Resetting JOBs (welding tasks) to the factory settings ............................................................. 113

7.3.1 Resetting a single JOB ............................................................................................... 113

7.3.2 Resetting all JOBs ...................................................................................................... 114

7.4 General operating problems ...................................................................................................... 114

7.4.1 Automation interface .................................................................................................. 114

7.5 Vent coolant circuit ..................................................................................................................... 115

8 Technical data .................................................................................................................................... 116

8.1 Phoenix 355 Progress puls MM TKM ........................................................................................ 116

9 Accessories ........................................................................................................................................ 117

9.1 General accessories .................................................................................................................. 117

9.2 Options ....................................................................................................................................... 117

9.3 Remote control/connecting and extension cable ....................................................................... 118

9.3.1 7-pole connection ....................................................................................................... 118

9.3.2 19-pole connection ..................................................................................................... 118

9.4 Computer communication .......................................................................................................... 118

10 Replaceable parts .............................................................................................................................. 119

10.1 Wire feed rollers ......................................................................................................................... 119

10.1.1 Wire feed rollers for steel wire .................................................................................... 119

10.1.2 Wire feed rollers for aluminium wire ........................................................................... 120

10.1.3 Wire feed rollers for cored wire .................................................................................. 120

10.1.4 Wire guide .................................................................................................................. 120

11 Appendix A ......................................................................................................................................... 121

11.1 JOB-List ..................................................................................................................................... 121

12 Appendix B ......................................................................................................................................... 128

12.1 Overview of EWM branches ...................................................................................................... 128

Safety instructions

Notes on the use of these operating instructions

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2 Safety instructions

2.1 Notes on the use of these operating instructions

DANGER

Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries.

• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.

• The hazard is also highlighted using a symbol on the edge of the page.

WARNING

Working or operating procedures which must be closely observed 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.

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 with a general warning symbol.

• The risk is explained using a symbol on the edge of the page.

Special technical points which users must observe.

Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet points, e.g.:

• Insert the welding current lead socket into the relevant socket and lock.

Safety instructions

Explanation of icons

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2.2 Explanation of icons

Symbol

Description

Symbol

Description

Indicates technical aspects which the user must observe.

Activate and release/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 light flashes green

Exit menu

Signal light lights up in red

Time representation (e.g.: wait 4 s/activate)

Signal light flashes red Interruption in the menu display (other

setting options possible)

Tool not required/do not use

Tool required/use

Safety instructions

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2.3 Safety instructions

WARNING

Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal!

• Carefully read 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!

WARNING

Risk of injury from electrical voltage! Voltages can cause potentially fatal electric shocks and burns on contact. Even low

voltages can cause a shock and lead to accidents.

• Never touch live components such as welding current sockets or stick, tungsten or wire electrodes!

• Always place torches and electrode holders on an insulated surface!

• Wear the full personal protective equipment (depending on the application)!

• The machine may only be opened by qualified personnel!

Hazard when interconnecting multiple power sources! If a number of power sources are to be connected in parallel or in series, only a

technical specialist may interconnect the sources as per standard IEC 60974-9:2010: Installation and use and German Accident Prevention Regulation BVG D1 (formerly VBG

15) or country-specific regulations.

Before commencing arc welding, a test must verify that the equipment cannot exceed the maximum permitted open circuit voltage.

• Only qualified personnel may connect the machine.

• When taking individual power sources out of operation, all mains and welding current leads

must be safely disconnected from the welding system as a whole. (Hazard due to reverse polarity voltage!)

• Do not interconnect welding machines with pole reversing switch (PWS series) or machines for AC welding since a minor error in operation can cause the welding voltages to be combined, which is not permitted.

Safety instructions

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WARNING

Risk of injury due to improper clothing! During arc welding, radiation, heat and voltage are sources of risk that cannot be

avoided. The user has to be equipped with the complete personal protective equipment at all times. The protective equipment has to include:

• Respiratory protection against hazardous substances and mixtures (fumes and vapours); otherwise implement suitable measures such as extraction facilities.

• Welding helmet with proper protection against ionizing radiation (IR and UV radiation) and heat.

• Dry welding clothing (shoes, gloves and body protection) to protect against warm environments with conditions comparable to ambient temperatures of 100 °C or higher and arcing and work on live components.

• Hearing protection against harming noise.

WARNING

Risk of injury due to radiation or heat! Arc radiation results in injury to skin and eyes.

Contact with hot workpieces and sparks results in burns.

• Use welding shield or welding helmet with the appropriate safety level (depending on the application)!

• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant regulations in the country in question!

• Protect persons not involved in the work against arc beams and the risk of glare using safety curtains!

WARNING

Explosion risk! Apparently harmless substances in closed containers may generate excessive pressure

when heated.

• Move containers with inflammable or explosive liquids away from the working area!

• Never heat explosive liquids, dusts or gases by welding or cutting!

Fire hazard! Due to the high temperatures, sparks, glowing parts and hot slag that occur during

welding, there is a risk of flames.

• Be watchful of potential sources of fire in the working area!

• Do not carry any easily inflammable objects, e.g. matches or lighters.

• Ensure suitable fire extinguishers are available in the working area!

• Thoroughly remove any residue of flammable materials from the workpiece prior to starting

to weld.

• Only further process workpieces after they have cooled down. Do not allow them to contact any flammable materials!

Safety instructions

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CAUTION

Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent

vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc!

• Ensure that there is sufficient fresh air!

• Keep solvent vapour away from the arc beam field!

• Wear suitable breathing apparatus if appropriate!

CAUTION

Noise exposure! Noise exceeding 70 dBA can cause permanent hearing damage!

• Wear suitable ear protection!

• Persons located within the working area must wear suitable ear protection!

Obligations of the operator! The respective national directives and laws must be complied with when operating the machine!

• Implementation of national legislation relating to framework directive 89/391/EEC on the introduction of measures to encourage improvements in the safety and health of workers at work and associated individual guidelines.

• In particular, directive 89/655/EEC concerning the minimum safety and health requirements for the use of work equipment by workers at work.

• The regulations applicable to occupational safety and accident prevention in the country concerned.

• Setting up and operating the machine as per IEC 60974.-9.

• Brief the user on safety-conscious work practices on a regular basis.

• Regularly inspect the machine as per IEC 60974.-4.

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.

Requirements for connection to the public mains network High-performance machines can influence the mains quality by taking current from the mains

network. For some types of machines, connection restrictions or requirements relating to the maximum possible line impedance or the necessary minimum supply capacity at the interface with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect, attention is also drawn to the machines' technical data. In this case, it is the responsibility of the operator, where necessary in consultation with the mains network operator, to ensure that the machine can be connected.

Safety instructions

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CAUTION

Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which

could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers.

• Observe the maintenance instructions > see 6.3 chapter!

• Unwind welding leads completely!

• Shield devices or equipment sensitive to radiation accordingly!

• The correct functioning of pacemakers may be affected (obtain advice from a doctor if

necessary).

According to IEC 60974-10, welding machines are divided into two classes of electromagnetic compatibility (the EMC class can be found in the Technical data) > see 8 chapter:

Class A machines are not intended for use in residential areas where the power supply comes

from the low-voltage public mains network. When ensuring the electromagnetic compatibility of class A machines, difficulties can arise in these areas due to interference not only in the supply lines but also in the form of radiated interference. Class B machines fulfil the EMC requirements in industrial as well as residential areas, including residential areas connected to the low-voltage public mains network.

Setting up and operating

When operating arc welding systems, in some cases, electro-magnetic interference can occur although all of the welding machines comply with the emission limits 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 user must consider the following: (see also EN 60974-10 Appendix A)

• Mains, control, signal and telecommunication lines

• Radios and televisions

• Computers and other control systems

• Safety equipment

• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing

aid

• Calibration and measuring equipment

• The immunity to interference of other equipment in the surrounding area

• The time of day at which the welding work must be carried out

Recommendations for reducing interference emission

• Mains connection, e.g. additional mains filter or shielding with a metal tube

• Maintenance of the arc welding system

• Welding leads should be as short as possible and run closely together along the ground

• Potential equalization

• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,

it should be connected by means of suitable capacitors.

• Shielding from other equipment in the surrounding area or the entire welding system

Safety instructions

Transport and installation

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2.4 Transport and installation

WARNING

Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause

serious injuries!

• Observe the instructions from the gas manufacturer and any relevant regulations concerning the use of compressed air!

• Do not attach any element to the shielding gas cylinder valve!

• Prevent the shielding gas cylinder from heating up.

CAUTION

Risk of accidents due to supply lines! During transport, attached supply lines (mains leads, control cables, etc.) can cause

risks, e.g. by causing connected machines to tip over and injure persons!

• Disconnect all supply lines before transport!

Risk of tipping! There is a risk of the machine tipping over and injuring persons or being damaged itself

during movement and set up. Tilt resistance is guaranteed up to an angle of 10° (according to IEC 60974-1).

• Set up and transport the machine on level, solid ground.

• Secure add-on parts using suitable equipment.

The units are designed for operation in an upright position! Operation in non-permissible positions can cause equipment damage.

• Only transport and operate in an upright position!

Accessory components and the power source itself can be damaged by incorrect connection!

• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.

• Comprehensive descriptions can be found in the operating instructions for the relevant accessory components.

• Accessory components are detected automatically after the power source is switched on.

Protective dust caps protect the connection sockets and therefore the machine against dirt and damage.

• The protective dust cap must be fitted if there is no accessory component being operated on that connection.

• The cap must be replaced if faulty or if lost!

Intended use

Documents which also apply

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3 Intended use

WARNING

Hazards due to improper usage! The machine has been constructed to the state of the art and any regulations and

standards applicable for use in industry and trade. It may only be used for the welding procedures indicated at the rating 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 used in line with its designated purpose and by trained or expert personnel!

• Do not improperly modify or convert the equipment!

Arc welding machine for standard and pulsed gas-shielded metal-arc welding with TIG welding and lift arc (touch starting) or MMA welding as secondary process. It may be possible to expand the functionality by using accessories (see the documentation in the relevant chapter).

3.1 Documents which also apply

3.1.1 Warranty

For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com!

3.1.2 Declaration of Conformity

The labelled machine complies with the following EC directives in terms of its design and construction:

• Low Voltage Directive (LVD)

• Electromagnetic Compatibility Directive (EMC)

• Restriction of Hazardous Substance (RoHS)

In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product.

3.1.3 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 hazard.

3.1.4 Service documents (spare parts and circuit diagrams)

WARNING

Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by

specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference.

• Appoint only skilled persons for repair work (trained service personnel)!

Original copies of the circuit diagrams are enclosed with the unit. Spare parts can be obtained from the relevant authorised dealer.

3.1.5 Calibration/Validation

We hereby confirm that this machine has been tested using calibrated measuring equipment, as stipulated in IEC/EN 60974, ISO/EN 17662, EN 50504, and complies with the admissible tolerances. Recommended calibration interval: 12 months

Machine description – quick overview

Front view

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4 Machine description – quick overview

4.1 Front view

Figure 4-1

Machine description – quick overview

Front view

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Item

Symbol

Description 0

1 Carrying handle

Transport bar

3 Protective cap

Cover for the wire feed mechanism and other operating elements. Depending on the machine series, additional stickers with information on the replacement parts and JOB lists will be located on the inside.

4 Wire spool inspection window

Check wire supply

5 Slide latch, lock for the protective cap

6 Welding torch connection (Euro torch connector)

Welding current, shielding gas and torch trigger integrated

7 Machine feet

8 Park socket, polarity selection plug

Retainer for the polarity selection plug in MMA mode or for transport.

9 19-pole connection socket (analogue)

For connecting analogue accessory components (remote control, welding torch control lead, etc.)

10 Connection socket, "+" welding current

• ----------- MIG/MAG cored wire welding: Workpiece connection

• ----------- TIG welding: Workpiece connection

• ----------- MMA welding: Workpiece connection

11 Welding current cable, polarity selection

Welding current to Euro torch connector/torch, for polarity selection

• ----------- MIG/MAG: Connection socket for “+” welding current

• ----------- Self-shielding flux cored wire/TIG: Connection socket, “-” welding current

• ----------- MMA: Park socket

12 "-" welding current connection socket

• ----------- MIG/MAG welding: Workpiece connection

• ----------- TIG welding: Welding current connection for welding torch

• ----------- MMA welding: electrode holder connection

Cooling air inlet

▼ optional, factory-fitted ▼

14 Key switch for protection against unauthorised use > see 5.9 chapter

1 ---------- changes possible,G front drive-4x-EX 0 ---------- changes not possible.

▲ optional, factory-fitted ▲

15 Machine control > see 4.3 chapter

16 Protective cap > see 5.1.4 chapter

Machine description – quick overview

Rear view

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4.2 Rear view

Figure 4-2

Machine description – quick overview

Rear view

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Item

Symbol

Description 0

1 Main switch, machine on/off

2 Connecting nipple G¼, shielding gas connection

▼ Retrofitting option ▼

3 19-pole mechanised welding interface (analogue)

> see 5.7.1 chapter

▲ Retrofitting option ▲

Cooling air outlet

5 External wire feed inlet

Pre-cut casing inlet for external wire feed.

6 7-pole connection socket (digital)

For connecting digital accessory components (documentation interface, robot interface or remote control, etc.).

7 8-pole connection socket

Cooling unit control lead

Mains connection cable > see 5.1.8 chapter

4-pole connection socket

Cooling unit voltage supply

Machine description – quick overview

Rear view

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4.2.1 Operating elements in the machine

Figure 4-3

Item

Symbol

Description 0

Key button, automatic cutout

Wire feed motor supply voltage fuse press to reset a triggered fuse

Welding torch function changeover switch (special welding torch required)

Changing over programs or JOBs Infinite adjustment of welding performance.

3 PC interface, serial (D-Sub connection socket, 9-pole) 4 Wire spool holder

5 Wire feed unit

Machine description – quick overview

Machine control – Operating elements

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4.3 Machine control – Operating elements

Figure 4-4

Item

Symbol

Description 0

1 Functional sequence > see 4.3.1 chapter

JOB-

LIST

Welding task push-button (JOB)

Select the welding task from the welding task list (JOB-LIST). The list can be found inside the protective cap on the wire feeder and in the appendix to these operating instructions.

3 Display, left

Welding current, material thickness, wire speed, hold values

4 Push-button, parameter selection left/power-saving mode

AMP ----- Welding current

-------- Material thickness > see 5.3.6.2 chapter

-------- Wire feed speed

Hold ------ After welding, the values used last are shown from the main program. The

signal light is illuminated.

STBY ---- Press for 2 s to put machine into power-saving mode.

To reactivate, activate one of the operating elements > see 5.11.3 chapter.

5 Display, JOB

Shows the currently selected welding task (JOB number).

6 Welding parameter setting, rotary dial

For setting the welding performance, for selecting the JOB (welding task) and for setting other welding parameters.

Machine description – quick overview

Machine control – Operating elements

099-005403-EW501

18.08.2016

Item

Symbol

Description 0

7 Select operating mode button

--------- Non-latched

------- Latched

-------- Signal light lights up in green: Special non-latched

---- Signal light lights up in red: MIG spot welding

-------- Special latched

8 Welding type push-button

------- Standard arc welding

---- Pulsed arc welding

9 Push-button, throttling effect (arc dynamics)

---- Arc is harder and more narrow

---- Arc is softer and wider

10 Arc length correction/selection of welding program, rotary dial

• ---------- Correction of the arc length from -9.9 V to +9.9 V.

• ---------- Selection of welding programs 0 to 15 (not possible if accessory components,

such as program torches, are connected).

11 Button, Parameter selection (right)

VOLT --- Welding voltage Prog ----- Program number kW ------- Welding performance display

------- Gas flow quantity (optional)

12 Display, right

Welding voltage, program number, motor current (wire feed mechanism)

13 Push-button gas test / rinse hose package > see 5.1.9.3 chapter

14 Push-button, wire inching

Potential- and gas-free inching of the wire electrode through the hose package to the welding torch > see 5.3.3.4 chapter.

Machine description – quick overview

Machine control – Operating elements

099-005403-EW501

18.08.2016

4.3.1 Function sequence

Figure 4-5

Item

Symbol

Description 0

1 Select welding parameters button

This button is used to select the welding parameters depending on the welding process and operating mode used.

2 Signal light, gas pre-flow time

Setting range 0.0 s to 20.0 s

3 Signal light, start program (P

START

)

• Wire speed:1% to 200% of the main program PA

• Correction of the arc length -9.9 V to +9.9 V

sec

Signal light, start time

Setting range, absolute 0.0 s to 20.0 s (0.1 s increments)

sec

Signal light, slope time program P

START

to main program PA

Setting range 0.0 s to 20.0 s (0.1 s increments)

6 Signal light, main program (PA)

• Wire speed WF-min. to WF-max.

• Correction of the arc length -9.9 V to +9.9 V

sec

Signal light, duration of main program PA

Setting range 0.1 s to 20.0 s (0.1 s increments). Used e.g. in connection with the super pulse function

8 Signal light, reduced main program (PB)

• Wire speed:1% to 200% of the main program PA

• Correction of the arc length -9.9 V to +9.9 V

sec

Signal light, duration reduced main program PB

Setting range 0.0 s to 20.0 s (0.1 s increments). Used e.g. in connection with the super pulse function.

sec

Signal light, slope time program PA (or PB) to end program P

END

Setting range 0.0 s to 20.0 s (0.1 s increments)

11 Signal light, end program (P

END

)

• Wire speed:1% to 200% of the main program PA

• Correction of the arc length -9.9 V to +9.9 V

sec

Signal light, duration of end program P

END

Setting range 0.0 s to 20.0 s (0.1 s increments)

13 Signal light, gas post-flow time

Machine description – quick overview

Machine control – Operating elements

099-005403-EW501

18.08.2016

Item

Symbol

Description 0

Super-

puls

Signal lamp, super pulse function

Lights up when the super pulse function is active.

Design and function

Transport and installation

099-005403-EW501

18.08.2016

5 Design and function

WARNING

Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal!

• Follow safety instructions on the opening pages of the operating instructions.

• Commissioning may only be carried out by persons who have the relevant expertise of

working with arc welding machines!

• Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead, interfaces) may only be connected when the machine is switched off!

5.1 Transport and installation

WARNING

Risk of accident due to improper transport of machines that must not be lifted! Do not lift or suspend the machine! The machine can drop and cause injuries! The

handles, straps or brackets are suitable for transport by hand only!

• The machine must not be suspended or lifted using a crane.

• Depending on machine type, equipment for lifting by crane or use while suspended is

available as a retrofitting option > see 9 chapter.

5.1.1 Ambient conditions

T he machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base!

• The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work.

• Safe operation of the machine must be guaranteed at all times.

Unusually high quantities 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)!

Design and function

Transport and installation

099-005403-EW501

18.08.2016

5.1.2 Machine cooling

Insufficient ventilation results in a reduction in performance and equipment damage.

• Observe the ambient conditions!

• Keep the cooling air inlet and outlet clear!

• Observe the minimum distance of 0.5 m from obstacles!

5.1.3 Workpiece lead, general

CAUTION

Risk of burning due to incorrect welding current connection! If the welding current plugs (machine connections) are not locked or if the workpiece

connection is contaminated (paint, corrosion), these connections and leads can heat up and cause burns when touched!

• Check welding current connections on a daily basis and lock by turning to the right when necessary.

• Clean workpiece connection thoroughly and secure properly. Do not use structural parts of the workpiece as welding current return lead!

5.1.4 Protective flap, welding machine control

Figure 5-1

Item

Symbol

Description 0

1 Protective cap

2 Lid

3 Bracket, protective cap

• Push the right-hand bracket of the protective cap to the right and remove the protective cap.

Design and function

Transport and installation

099-005403-EW501

18.08.2016

5.1.5 Welding torch holder

The item described in the following is part of the machine´s scope of delivery.

Figure 5-2

Item

Symbol

Description 0

1 Crossmember of the transport handle

2 Torch holder

3 Fan-type lock washers

4 Fixing screws (x 4)

• Use the mounting screws to screw the torch holder onto the crossmember of the transport handle.

• Insert the welding torch into the welding torch holder as shown.

Design and function

Transport and installation

099-005403-EW501

18.08.2016

5.1.6 Welding torch cooling system

5.1.6.1 Cooling module connection

Figure 5-3

Item

Symbol

Description 0

4-pole connection socket

Cooling unit voltage supply

2 8-pole connection socket

Cooling unit control lead

3 Cooling module

• Insert and lock the 4-pole supply plug on the cooling unit into the 4-pole connection socket on the welding machine.

• Insert and lock the 8-pole control lead plug on the cooling unit into the 8-pole connection socket on the welding machine.

Design and function

Transport and installation

099-005403-EW501

18.08.2016

5.1.7 Notes on the installation of welding current leads

Incorrectly installed welding current leads can cause faults 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 power sources with HF igniter (TIG) for as long as possible in parallel with a distance of 20 cm to avoid HF sparkover.

Always keep a distance of at least 20 cm to leads of other power sources to avoid interferences

Always keep leads as short as possible! For optimum welding results max. 30 m (welding lead + intermediate hose package + torch lead).

Figure 5-4

Use an individual welding lead to the workpiece for each welding machine!

Figure 5-5

Design and function

Transport and installation

099-005403-EW501

18.08.2016

Fully unroll welding current leads, torch hose packages and intermediate hose packages. Avoid loops!

Always keep leads as short as possible!

Lay any excess cable lengths in meanders.

Figure 5-6

5.1.7.1 Stray welding currents

WARNING

Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and

electronic devices and cause overheating of components, leading to fire.

• Check that all welding current connections are firmly secured and electrical connections are in perfect condition.

• Set up, attach or suspend all conductive power source components such as casing, transport vehicles and crane frames so they are insulated.

• Do not place any other electronic devices such as drills or angle grinders on the power source, transport vehicle or crane frames unless they are insulated.

• Always put welding torches and electrode holders on an insulated surface when they are not in use.

Figure 5-7

Design and function

Transport and installation

099-005403-EW501

18.08.2016

5.1.8 Mains connection

DANGER

Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property!

• Only operate machine using a socket that has correctly fitted protective earth.

• The mains voltage indicated on the rating plate must match the supply voltage.

• If a new mains plug must be fitted, only an electrician may do so as per the relevant

national legislation or regulations.

• Mains plug, socket and lead must be checked by an electrician on a regular basis.

• When operating the generator, always ensure it is earthed as stipulated in the operating

instructions. The network created must be suitable for operating machines according to protection class I.

5.1.8.1 Mains configuration

The machine may be connected to:

• a three-phase system with four conductors and an earthed neutral conductor

• a three-phase system with three conductors of which any one can be earthed,

e.g. the outer conductor

Figure 5-8

Legend

Item

Designation

Colour code

Outer conductor 1

brown

Outer conductor 2

black

Outer conductor 3

grey

Neutral conductor

blue

Protective conductor

green-yellow

• Insert mains plug of the switched-off machine into the appropriate socket.

Design and function

Transport and installation

099-005403-EW501

18.08.2016

5.1.9 Shielding gas supply (shielding gas cylinder for welding machine)

WARNING

Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders

can cause serious injuries!

• Place shielding gas cylinder into the designated holder and secure with fastening elements (chain/belt)!

• Attach the fastening elements within the upper half of the shielding gas cylinder!

• The fastening elements must tightly enclose the shielding gas cylinder!

An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results. In addition, a blocked shielding gas supply may result in the welding torch being destroyed.

• Always re-fit the yellow protective cap when not using the shielding gas connection.

• All shielding gas connections must be gas tight.

5.1.9.1 Pressure regulator connection

Figure 5-9

Item

Symbol

Description 0

1 Pressure regulator

2 Shielding gas cylinder

3 Output side of the pressure regulator

4 Cylinder valve

• Before connecting the pressure regulator to the gas cylinder, open the cylinder valve briefly to blow out any dirt.

• Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight.

• Screw gas hose connection crown nut onto the output side of the pressure regulator.

Design and function

Transport and installation

099-005403-EW501

18.08.2016

5.1.9.2 Shielding gas hose connection

Figure 5-10

Item

Symbol

Description 0

1 Connecting nipple G¼, shielding gas connection

• Connect crown nut of the shielding gas line to the G¼“ connecting nipple.

Design and function

Transport and installation

099-005403-EW501

18.08.2016

5.1.9.3 Gas test – setting the shielding gas volume

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 shielding gas quantity to suit the welding task!

• Slowly open the gas cylinder valve.

• Open the pressure regulator.

• Switch on the power source at the main switch.

• Set the relevant gas quantity for the application on the pressure regulator.

• The gas test can be triggered by briefly pressing the Gas test/Rinse hose package push-button

either at the control or underneath the protective cap next to wire feeder (welding voltage and wire feed motor remain switched off, no unintentional arc ignition).

Shielding gas flows for around 25 seconds or until the button is pressed again.

Setting instructions

Welding process

Recommended shielding gas quantity

MAG welding

Wire diameter x 11.5 = l/min

MIG brazing

Wire diameter x 11.5 = l/min

MIG welding (aluminium)

Wire diameter x 13.5 = l/min (100 % argon)

TIG

Gas nozzle diameter in mm corresponds to l/min gas throughput

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% Ar/25% He

1.14

50% Ar/50% He

1.35

25% Ar/75% He

1.75

100% He

3.16

Design and function

Welding data display

099-005403-EW501

18.08.2016

5.2 Welding data display

To the left and right of the control displays are the "Parameter selection" buttons ( ). They are used to select welding parameters to be displayed.

Each press of the button advances the display to the next parameter (LEDs next to the button indicate the selection). After the last parameter is reached, the system starts again from the beginning.

Figure 5-11

The display shows:

• Nominal values (before welding)

• Actual values (during welding)

• Hold values (after welding)

MIG/MAG

Parameter

Nominal values

Actual values

Hold values

Welding current

  

Material thickness

  

Wire feed speed

  

Welding voltage

  

Welding performance

  

TIG

Parameter

Nominal values

Actual values

Hold values

Welding current

  

Welding voltage

  

Welding performance



MMA

Parameter

Nominal values

Actual values

Hold values

Welding current

  

Welding voltage

  

Welding performance

  

When settings are changed (e.g. wire feed speed) the display immediately switches to nominal value setting.

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

5.3 MIG/MAG welding

5.3.1 Welding torch and workpiece line connection

On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a steel liner. Conversion is necessary if a welding torch with a liner is used!

• Operate welding torches with a liner > with a guide tube.

• Operate welding torches with a steel liner > with a capillary tube.

Depending on the wire electrode diameter or type, either a steel liner or liner with the correct inner diameter must be inserted in the torch!

Recommendation:

• Use a steel liner when welding hard, unalloyed wire electrodes (steel).

• Use a chrome nickel liner when welding hard, high-alloy wire electrodes (CrNi).

• Use a liner to weld or braze soft wire electrodes, high-alloy wire electrodes or aluminium materials.

Preparation for connecting welding torches with a liner:

• Push forward the capillary tube on the wire feed side in the direction of the Euro torch connector and remove it there.

• Insert the liner guide tube from the Euro torch connector side.

• Carefully insert the welding torch connector with as yet too long a liner into the Euro torch connector

and secure with a crown nut.

• Cut off the liner with a liner cutter > see 9 chapter just before the wire feed roller.

• Loosen the welding torch connector and remove.

• Carefully chamfer the cut off end of the liner with a liner sharpener > see 9 chapter and sharpen.

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

5.3.2 Welding torch and workpiece line connection

On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a steel liner. Conversion is necessary if a welding torch with a liner is used!

• Operate welding torches with a liner > with a guide tube.

• Operate welding torches with a steel liner > with a capillary tube.

Depending on the wire electrode diameter or type, either a steel liner or liner with the correct inner diameter must be inserted in the torch!

Recommendation:

• Use a steel liner when welding hard, unalloyed wire electrodes (steel).

• Use a chrome nickel liner when welding hard, high-alloy wire electrodes (CrNi).

• Use a liner to weld or braze soft wire electrodes, high-alloy wire electrodes or aluminium materials.

Preparation for connecting welding torches with a liner:

• Push forward the capillary tube on the wire feed side in the direction of the Euro torch connector and remove it there.

• Insert the liner guide tube from the Euro torch connector side.

• Carefully insert the welding torch connector with as yet too long a liner into the Euro torch connector

and secure with a crown nut.

• Cut off the liner with a liner cutter > see 9 chapter just before the wire feed roller.

• Loosen the welding torch connector and remove.

• Carefully chamfer the cut off end of the liner with a liner sharpener > see 9 chapter and sharpen.

Some wire electrodes (e.g. self-shielding cored wire) are welded using negative polarity. In this case, the welding current 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!

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

Figure 5-12

Item

Symbol

Description 0

1 Welding torch 2 Welding torch hose package

3 Welding torch connection (Euro or Dinse torch connector)

Welding current, shielding gas and torch trigger integrated

4 19-pole connection socket (analogue)

Connection for welding torch control lead

5 Welding current cable, polarity selection

Welding current to central connection/torch. Permits polarity selection for MIG/MAG welding.

• ---------- Standard applications > Connection for "+" welding current connection socket

6 "-" welding current connection socket

• ---------- MIG/MAG welding: Workpiece connection

7 Workpiece

• Insert the central plug for the welding torch into the central connector and screw together with crown nut.

• Insert the plug on the workpiece lead into the "-" welding current connection socket and lock.

• Welding current lead, insert polarity selection into the "+" welding current connection socket and lock.

Where applicable:

• Insert the welding torch control cable into the 19-pole connection socket and lock (MIG/MAG torches with additional control cables only).

• Lock connecting nipples of the cooling water tubes into the corresponding quick connect couplings: Return line red to quick connect coupling, red (coolant return) and supply line blue to quick connect coupling, blue (coolant supply).

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

5.3.3 Wire feed

CAUTION

Risk of injury due to moving parts! The wire feeders are equipped with moving parts, which can trap hands, hair, clothing

or tools and thus injure persons!

• Do not reach into rotating or moving parts or drive components!

• Keep casing covers or protective caps closed during operation!

Risk of injury due to welding wire escaping in an unpredictable manner! Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may

escape in an uncontrolled manner and injure persons!

• Before mains connection, set up the complete wire guide system from the wire spool to the welding torch!

• Check wire guide at regular intervals!

• Keep all casing covers or protective caps closed during operation!

5.3.3.1 Open the protective flap of the wire feeder

To perform the following steps, the protective flap of the wire feeder needs to be opened. Make sure to close the protective flap again before starting to work.

• Unlock and open protective flap.

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

5.3.3.2 Inserting the wire spool

CAUTION

Risk of injury due to incorrectly secured wire spool. If the wire spool is not secured properly, it may come loose from the wire spool support

and fall to the ground, causing damage to the machine and injuries.

• Make sure to correctly fasten the wire spool to the wire spool support.

• Before you start working, always check the wire spool is securely fastened.

Standard D300 wire spool holder can be used. Adapters > see 9 chapter are required when using standardised basket coils (DIN 8559).

Figure 5-13

Item

Symbol

Description 0

1 Carrier pin

For fixing the wire spool

2 Knurled nut

For fixing the wire spool

• Loosen knurled nut from spool holder.

• Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore.

• Fasten wire spool using knurled nut.

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

5.3.3.3 Changing the wire feed rollers

Figure 5-14

Item

Symbol

Description 0

1 Tommy

The tommy is used to secure the closure brackets of the wire feed rollers.

2 Closure bracket

The closure brackets are used to secure the wire feed rollers.

3 Feed roll tensioner

Fixing 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).

• Fold the closure brackets outwards by 90°.

• Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip

upwards).

• Remove the wire feed rollers from the roller support.

• Select new wire feed rollers accoridng to the Wire feed roller overview table and reassemble the wire

feed mechanism in reverse order.

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

Unsatisfactory welding results due to faulty wire feeding! The wire feed rolls must be suitable for the diameter of the wire and the material. The wire feed

rolls are colour-coded to facilitate distinction (see the Wire feed roll overview table). When working with a wire diameter of > 1.6 mm the drive has to be converted for the wire feed kit ON WF 2,0-3,2MM EFEED > see 10 chapter.

Wire feed roller overview table

Material

Diameter

Colour code

Groove form

 mm

 inch

Steel Stainless steel Brazing

0.6

.023

monochrome

light pink

V-groove

0.8

.030

white

0.9/1.0

.035/.040

blue

1.2

045

red

1.4

052

green

1.6

060

black

2.0

.080

grey

2.4

.095

brown

2.8

.110

Light green

3.2

.125

purple

Aluminium

0.8

.030

bichrome

white

yellow

U-groove

0.9/1.0

.035/.040

blue

1.2

.045

red

1.6

.060

black

2.0

.080

grey

2.4

.095

brown

2.8

.110

Light green

3.2

.125

purple

Flux cored wire

0.8

.030

bichrome

white

orange

V-groove,

knurled

0.9

1.0

.035 .040

blue

1.2

.045

red

1.4

.052

green

1.6

.060

black

2.0

.080

grey

2.4

.095

brown

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

5.3.3.4 Inching the wire electrode

CAUTION

Risk of injury due to welding wire escaping from the welding torch! The welding wire can escape from the welding torch at high speed and cause bodily

injury including injuries to the face and eyes!

• Never direct the welding torch towards your own body or towards other persons!

Incorrect contact pressure will cause extensive wear of the wire feed rollers!

• With the adjusting nuts of the pressure units set the contact pressure so that the wire electrode is conveyed but will still slip through if the wire spool jams.

• Set the contact pressure of the front rollers (in wire feed direction) to a higher value!

The inching speed is infinitely adjustable by simultaneously pressing the wire inching pushbutton and turning the wire speed rotary knob. The left display shows the wire feed speed selected, the right display shows the current motor current of the wire feed mechanism.

Figure 5-15

Item

Symbol

Description 0

1 Welding wire

2 Wire feed nipple

3 Guide tube

4 Adjusting nut

• Extend and lay out the torch hose package.

• Carefully unwind the welding wire from the wire spool and insert through the wire feed nipples up to

the wire feed rollers.

• Press the inching push-button (the drive catches the welding wire and automatically guides it to the welding torch outlet).

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

A prerequisite for the automatic inching process is the correct preparation of the wire guide, especially in the capillary and wire guide tube area > see 5.3.1 chapter.

• The contact pressure has to be adjusted separately for each side (wire inlet/outlet) at the feed roll tensioner setting nuts depending on the welding consumable used. A table with the setting values can be found on a sticker near the wire drive.

Version 1: left hand mounting

Version 2: right hand mounting

Figure 5-16

Automatic inching stop

Touch the welding torch against the workpiece during inching. Inching of the welding wire will stop as soon it touches the workpiece.

5.3.3.5 Spool brake setting

Figure 5-17

Item

Symbol

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.

Tighten the spool brake until the wire spool no longer turns when the wire feed motor stops but without it jamming during operation!

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

5.3.4 Definition of MIG/MAG welding tasks

This machine series offers user-friendly operation and a multitude of features.

• Various welding tasks (JOBs) consisting of welding procedure, material type, wire diameter and shielding gas type have been predefined > see 11.1 chapter.

• The system calculates the required process parameters depending on the operating point specified (one-knob operation via wire feed speed rotary transducer).

• You can adjust additional parameters at the machine control or using the PC300.NET welding parameter software, if required.

5.3.5 Welding task selection

5.3.5.1 Basic welding parameters

You can only change the JOB number when no welding current is flowing.

Figure 5-18

Item

Symbol

Description 0

JOB-

LIST

Welding task push-button (JOB)

Select the welding task from the welding task list (JOB-LIST). The list can be found inside the protective cap on the wire feeder and in the appendix to these operating instructions.

2 Welding parameter setting, rotary dial

For setting the welding performance, for selecting the JOB (welding task) and for setting other welding parameters.

3 Select operating mode button

--------- Non-latched

-------- Latched

--------- Signal light lights up in green: Special non-latched

---- Signal light lights up in red: MIG spot welding

-------- Special latched

4 Welding type push-button

-------- Standard arc welding

---- Pulsed arc welding

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

5.3.5.2 Choke effect / dynamics

Setting range: 40: Arc hard and narrow, deeper fusion penetration.

-40: Arc soft and wide.

ENTER

EXIT

Figure 5-19

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

5.3.5.3 superPuls

In superPuls mode, the program toggles between the main program (PA) and the reduced main program (PB). This function is e.g. used for thin sheet welding to reduce the heat input in a controlled manner or for positional welding without the need for weaving.

The combination of superPuls and other EWM welding processes offers a multitude of possibilities. For example, to enable the welding of vertical-up welds without the "Christmas tree" technique, when selecting program 1 the relevant superPuls variant (depending on the material) is activated as well. The required superPuls parameters are defined ex works.

The welding power can be represented as average value (ex works) or solely as program A value. If the average value display is activated the signal lights of the main (PA) and reduced main program (PB) are illuminated simultaneously. The display variants can be toggled using special parameter P19,.

ENTER EXIT

Figure 5-20

Display

Setting/selection

Selects superPuls

Switches function on or off.

Switch on

Switching on machine function

Switch off

Switching off machine function

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

5.3.5.4 Burn-back

ENTER

EXIT

Figure 5-21

Display

Setting/selection

menu burn back

Set burn back

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

5.3.6 MIG/MAG operating point

The operating point (welding output) is specified using the principle of MIG/MAG one-dial operation, i.e. the user need only specify the operating point by setting the required wire speed, for example, and the digital system will calculate the optimum values for welding current and voltage (operating point).

The operating point setting can also be specified using the accessory components such as the remote control, welding torch, etc.

5.3.6.1 Selecting the display unit

Figure 5-22

Figure 5-23

Design and function

MIG/MAG welding

099-005403-EW501

18.08.2016

5.3.6.2 Operating point setting using material thickness

Plate thickness details in welding programs generally refer to fillet welds in the PB welding position. They should be regarded as guideline values and may differ in other welding positions.

Application example

Aluminium is to be welded.

• Material = AlMg,

• Gas = Ar 100%,

• Wire diameter = 1.2 mm

The correct wire speed is not known and is to be determined.

• Select the appropriate JOB ( > see 11.1 chapter)

• Switch to the material thickness display

• Set the material thickness as appropriate (e.g. 5 mm)

• Switch to the wire speed display

The resulting wire speed will be shown (e.g. 8.4 m/min).

Figure 5-24

5.3.6.3 Arc length correction setting

Figure 5-25

5.3.6.4 Accessory components for operating point setting

The operating point can also be set with various accessory components such as

• remote controls

• special torches

• PC software

• robot and industrial bus interfaces (optional interface for automated welding required – not possible for

all machines in this series!)

For an overview of the accessory components > see 9 chapter See the operating instructions for the machine in question for a more detailed description of the individual machines and their functions.

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5.3.7 forceArc / forceArc puls

Low-heat, directionally stable and powerful high-performance arc with deep fusion penetration for the upper power range Unalloyed, low-alloy and high-alloy steels as well as high-tensile fine-grained steels.

Figure 5-26

• Smaller included angle due to deep penetration and directionally stable arc

• Excellent root and sidewall fusion

• Secure welding also with very long stick-outs

• Reduced undercuts

• Un-, low- and high-alloyed steels as well as high-tensile fine-grained building steels

• Manual and automated applications

forceArc welding from:

Wire Ø (mm)

0.8 1 1.2

1.6

Material

Gas

JOB

Steel

Ar 91–99%

190

17.0

254

12.0

255

9.5

256

7.0

Ar 80–90%

189

17.0

179

12.0

180

9.5

181

6.0

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.

As with pulse arc welding, it is important to make sure of a good welding current connection.

• Keep welding current cables as short as possible and ensure that cable cross-sections are adequate!

• Fully unroll welding current cables, torche hose packages and, if applicable, intermediate hose

packages. Avoid loops!

• Use welding torches, preferably water-cooled, that are suitable for the higher power range.

• Use welding wire with adequate copper coating when welding steel. The wire spool should have layer

spooling.

Unstable arc! Welding current cables that are not fully unrolled can cause faults in the arc (flickering).

• Fully unroll welding current cables, torch hose packages and, if applicable, intermediate hose packages. Avoid loops!

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5.3.8 rootArc/rootArc puls

Short arc with perfect weld modelling capabilities for effortless gap bridging, especially for positional welding

Figure 5-27

• Reduced spatter compared to standard short arc

• Good root formation and secure sidewall fusion

• Un-alloyed and low-alloy steels

• Manual and automated applications

rootArc welding up to:

Wire Ø (mm)

0.6

0.8

0.9 1 1.2

1.6

Material

Gas

JOB

Steel

CO2

- - - - - - 204

7.0

205

5.0 - -

Ar 80–90%

- - - - - - 206

8.0

207

6.0 - -

Unstable arc! Welding current cables that are not fully unrolled can cause faults in the arc (flickering).

• Fully unroll welding current cables, torch hose packages and, if applicable, intermediate hose packages. Avoid loops!

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5.3.9 MIG/MAG functional sequences / operating modes

There are optimum pre-sets for welding parameters such as gas pre-flow and burn back, etc. for numerous applications (although these can also be changed if required).

5.3.9.1 Explanation of signs and functions

Symbol

Meaning

Press torch trigger

Release torch trigger

Tap torch trigger (press briefly and release)

Shielding gas flowing

Welding output

Wire electrode is being conveyed Wire creep

Wire burn-back

Gas pre-flows

Gas post-flows Non-latched

Special, non-latched

Latched

Special, latched

Time

START

Ignition program

Main program

Reduced main program

END

End program

Spot time

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Non-latched mode

Figure 5-28

Step 1

• Press and hold torch trigger.

• Shielding 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 speed.

Step 2

• Release torch trigger.

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

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Non-latched operation with superpulse

Figure 5-29

Step 1

• Press and hold torch trigger.

• Shielding 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.

• Start the super pulse function beginning with main program PA:

The welding parameters change at the specified times between main program PA and the reduced main program PB.

Step 2

• Release torch trigger.

• Super pulse function is ended.

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

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Special, non-latched

Figure 5-30

Step 1

• Press and hold torch trigger

• Shielding 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 is flowing (start

program P

START

for the time t

start

)

• Slope to main program PA.

Step 2

• Release torch trigger

• Slope to end program P

END

for the time t

end

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

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Spot welding

Figure 5-31

The ignition time t

start

must be added to the spot time t2.

1st cycle

• Press and hold torch trigger

• Shielding 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 is flowing (start program P

START

, spot time starts)

• Slope to main program PA

• After the set spot time elapses, slope goes to end program P

END

• Wire feed motor stop welding.

• Arc is extinguished after the pre-selected wire burn-back time elapses

• Gas post-flow time elapses.

2nd cycle

• Release torch trigger

Releasing the torch trigger (step 2) interrupts the welding process even if the spot time has not yet elapsed (slope to end program P

END

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Special, non-latched with superpulse

Figure 5-32

Step 1

• Press and hold torch trigger

• Shielding 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 is flowing (start

program P

START

for the time t

start

• Slope on main program PA.

• Start the super pulse function beginning with main program PA:

The welding parameters change at the specified times between main program PA and the reduced main program PB.

Step 2

• Release torch trigger

• Super pulse function is ended.

• Slope to end program P

END

for the time t

end

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

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Latched mode

Figure 5-33

Step 1

• Press and hold torch trigger

• Shielding 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 WF speed (main program PA).

Step 2

• Release torch trigger (no effect)

Step 3

• Press torch trigger (no effect)

Step 4

• Release torch trigger

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

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Latched mode with superpulse

Figure 5-34

Step 1:

• Press and hold torch trigger

• Shielding 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.

• Start the super pulse function beginning with main program PA.

The welding parameters change at the specified times between main program PA and the reduced main program PB.

Step 2:

• Release torch trigger (no effect)

Step 3:

• Press torch trigger (no effect)

Step 4:

• Release torch trigger

• Super pulse function is ended.

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

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Latched with changing welding method (process switching)

For machine versions with pulsed arc welding procedures only.

To activate or set the function > see 5.3.16 chapter.

Figure 5-35

1st cycle:

• Press and hold torch trigger

• Shielding 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

• Start the process alternation starting with process PA:

The welding processes alternate between the process PA stored in the JOB and the opposite process PB at the specified times (t2 and t3)

If a standard process is stored in the JOB, this means that there is a permanent alternation between the processes, starting with the standard process and followed by the pulse process. The same applies if the situation is reversed.

2nd cycle:

• Release torch trigger (no effect)

3rd cycle:

• Press torch trigger (no effect)

4th cycle:

• Release torch trigger

• Super pulse function is ended

• WF motor stops

• Arc is extinguished after the pre-selected wire burn-back time elapses

• Gas post-flow time elapses

This function can be activated using the PC300.NET software. Refer to the software operating instructions.

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Latched special

Figure 5-36

Step 1

• Press and hold torch trigger

• Shielding 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 is flowing (start

program P

START

)

Step 2

• Release torch trigger

• Slope to main program PA.

The slope on main program PA is given at the earliest after the set time t

START

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.

Step 3

• Press and hold torch trigger

• Slope to end program P

END

Step 4

• Release torch trigger

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

Prevent tapping (brief press and release within 0.3 seconds)

If the welding current is to be prevented from switching over to the reduced main program PB by tapping, the parameter value for WF3 needs to be set to 100% (PA = PB) in the program sequence.

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Special latched with changing welding method by tapping (process switching)

For machine versions with pulsed arc welding procedures only.

To activate or set the function > see 5.3.16 chapter.

Figure 5-37

1st cycle

• Press and hold torch trigger.

• Shielding 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 is flowing (start

program P

START

)

2nd cycle

• Release torch trigger

• Slope on main program PA

The slope on main program PA is given at the earliest after the set time t

START

elapses and at the latest when the torch trigger is released. Tapping (pressing the torch trigger for less than 0.3 sec.) changes over the welding process (PB).

If a standard process has been defined in the main program, tapping changes to the pulse process, and tapping again will return to the standard process, etc.

3rd cycle

• Press and hold torch trigger

• Slope to end program P

END

4th cycle

• Release torch trigger

• WF motor stops

• Arc is extinguished after the pre-selected wire burn-back time elapses

• Gas post-flow time elapses

This function can be activated using the PC300.Net software. Refer to the software operating instructions.

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Special latched with changing welding method (process switching)

For machine versions with pulsed arc welding procedures only.

Figure 5-38

1st cycle

• Press and hold torch trigger

• Shielding 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 is flowing (start

program P

START

for the time t

start

)

2nd cycle

• Release torch trigger

• Slope on main program PA

• Start the process alternation starting with process PA:

The welding processes alternate between the process PA stored in the JOB and the opposite process PB at the specified times (t2 and t3)

3rd cycle

• Press the torch trigger

• Super pulse function is ended

• Slope in the end program P

END

for the time t

end

4th cycle

• Release torch trigger

• WF motor stops

• Arc is extinguished after the pre-selected wire burn-back time elapses

• Gas post-flow time elapses

This function can be activated using the PC300.Net software. Refer to the software operating instructions.

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Special, latched with superpulse

Figure 5-39

Step 1

• Press and hold torch trigger

• Shielding 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 is flowing (start

program P

START

for the time t

start

Step 2

• Release torch trigger

• Slope on main program PA.

• Start the super pulse function beginning with main program PA:

The welding parameters change at the specified times between main program PA and the reduced main program PB.

Step 3

• Press the torch trigger.

• Super pulse function is ended.

• Slope in the end program P

END

for the time t

end

Step 4

• Release torch trigger

• WF motor stops.

• Arc is extinguished after the preselected wire burn-back time expires.

• Gas post-flow time elapses.

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5.3.10 Conventional MIG/MAG Welding (GMAW non synergic)

It is only possible to change the JOB number when no welding current is flowing.

• With wire-feed speeds less than 8 m/min select JOB 188.

• With wire-feed speeds over 8 m/min select JOB 187.

EXIT

Figure 5-40

5.3.10.1 Setting the operating point (welding output)

Figure 5-41

Figure 5-42

Figure 5-43

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5.3.11 MIG/MAG program sequence ("Program steps" mode)

Certain materials, such as aluminium, require special functions in order to be able to weld them safely and at high quality. The latched special operating mode is used here with the following programs:

• Start program P

START

(reduction of cool points at the start of the seam)

• Main program PA (continuous welding)

• Reduced main program PB (targeted heat reduction)

• End program P

END)

(minimisation of end craters via targeted heat reduction)

The programs include the parameters wire speed (operating point), arc length correction, slope times, program duration, etc.

Figure 5-44

In every JOB, separate settings can be made for the ignition program, reduced main program and end program as to whether or not to alternate with the pulse process.

These properties are stored on the welding machine with the JOB. This means that in the factory settings, the pulse process is active during the end program in all forceArc JOBs.

To activate or set the function > see 5.3.16 chapter.

5.3.11.1 Selection of the program sequence parameter

ENTER

Figure 5-45

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5.3.11.2 MIG/MAG overview of parameters

START

, PB, and P

END

are set as relative programs ex faxtory. They relate to percentages of the wire feed value of the main program PA. These programs can also be set in an absolute manner, if desired (see Setting of special parameter P21).

Figure 5-46

Basic Parameters

Item

Meaning / Explanation

Setting Range

1 1

Gas pre-flow time

0.0s to 20.0s

2 2

START

Wire speed, relative Arc length correction

1% to 200%

-9.9V to +9.9V

3 3

Duration

0.0s to 20.0s

4 4

Slope duration from P

START

to PA

0.0s to 20.0s

5 5

PA Wire speed, absolute

0.1 m/min to 40 m/min

6 7

Duration (spot time and superpulse)

0.01s to 20.0s

7 8

PB Wire speed, relative Arc length correction, relative

1% to 200%

-9.9V to +9.9V

8 9

Duration

0.01s to 20.0s

9 1

Slope duration from PA to P

END

0.0s to 20s

10 1

END

Wire speed, relative Arc length correction

1% to 200%

-9.9V to +9.9V

11 1

Duration (superpulse)

0.0s to 20s

12 1

Gas post-flow time

0.0s to 20s

13 1

superPuls

On / Off

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5.3.11.3 Example, tack welding (non-latched)

Figure 5-47

Basic parameters

Parameter

Meaning / explanation

Setting range

GASstr

Gas pre-flow time

0.0s to 20.0s

GASend:

Gas post-flow time

0.0s to 20s

RUECK

Wire burn-back length

2 to 500

"PA" main program

Parameter

Meaning / explanation

Setting range

Setting the wire speed

5.3.11.4 Example, aluminium tack welding (non-latched special)

Figure 5-48

Basic parameters

Welding parameter

Meaning / explanation

Setting range

GASstr

Gas pre-flow time

0.0s to 20.0s

GASend:

Gas post-flow time

0.0s to 20.0s

RUECK

Wire burn-back length

2 to 500

START

" start program

Welding parameter

Meaning / explanation

Setting range

DVstart

Wire speed

0% to 200%

Ustart

Arc length correction

-9.9V to +9.9V

tstart

Duration

0.0s to 20s

"PA" main program

Welding parameter

Meaning / explanation

Setting range

Setting the wire speed

END

" end-crater program

Welding parameter

Meaning / explanation

Setting range

DVend

Wire speed

0% to 200%

Uend

Arc length correction

-9.9V to +9.9V

tend

Duration

0.0s to 20s

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5.3.11.5 Example, aluminium welding (latched special)

Figure 5-49

Basic parameters

Welding parameter

Meaning / explanation

Setting range

GASstr

Gas pre-flow time

0.0s to 20.0s

GASend:

Gas post-flow time

0.0s to 20.0s

RUECK

Wire burn-back length

2 to 500

START

" start program

Welding parameter

Meaning / explanation

Setting range

DVstart

Wire speed

0% to 200%

ustart

Arc length correction

-9.9V to +9.9V

tstart

Duration

0.0s to 20s

"PA" main program

Welding parameter

Meaning / explanation

Setting range

Setting the wire speed

"PB" reduced main program

Welding parameter

Meaning / explanation

Setting range

DV3

Wire speed

0% to 200%

Arc length correction

-9.9V to +9.9V

END

" end-crater program

Welding parameter

Meaning / explanation

Setting range

tSend

Slope duration from PA or PB to P

END

0.0s to 20s

DVend

Wire speed

0% to 200%

Uend

Arc length correction

-9.9V to +9.9V

tend

Duration

0.0s to 20s

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5.3.11.6 Example, visible seams (latched super pulse)

Figure 5-50

Basic parameters

Welding parameter

Meaning / explanation

Setting range

GASstr

Gas pre-flow time

0.0s to 20.0s

GASend:

Gas post-flow time

0.0s to 20.0s

RUECK

Wire burn-back length

2 to 500

START

" start program

Welding parameter

Meaning / explanation

Setting range

DVstart

Wire speed

0% to 200%

ustart

Arc length correction

-9.9V to +9.9V

tstart

Duration

0.0s to 20s

"PA" main program

Welding parameter

Meaning / explanation

Setting range

tS1

Slope duration from P

START

to PA

0.0s to 20s

DV3

Setting the wire speed

0% to 200%

Duration

0.1s to 20s

tS3

Slope duration from PB to PA

0.0s to 20s

"PB" reduced main program

Welding parameter

Meaning / explanation

Setting range

tS2

Slope duration from PA to PB

0.0s to 20s

DV3

Wire speed

0% to 200%

Arc length correction

-9.9V to +9.9V

Duration

0.1s to 20s

END

" end-crater program

Welding parameter

Meaning / explanation

Setting range

tSend

Slope duration from PA or PB to P

END

0.0s to 20s

DVend

Wire speed

0% to 200%

Uend

Arc length correction

-9.9V to +9.9V

tend

Duration

0.0s to 20s

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5.3.12 Main program A mode

Different welding tasks or positions on a workpiece demand various welding performances (operating points) or welding programs. The following parameters are stored in each of the up to 16 programs:

• Operating mode

• Welding type

• superPuls (ON/OFF)

• Wire feed speed (DV2)

• Voltage correction (U2)

• Dynamics (DYN2)

The user can change the main program welding parameters using the following components.

Program

switching

JOB switching

Program

Operating mode

Welding process

superPuls

Wire speed

Voltage

correction

Dynamics

M3.7x

Wire feeder control

Yes

P1...15

Yes

R20

Remote control

Yes

P1...9

Yes 1)

R40

Remote control

Yes

R50

Remote control

Yes

P1...15

PC 300.NET

Software

Yes

P1...15

Yes

Up/Down

Welding torch

Yes

P1...9

2 Up/Down

Welding torch

Yes

P1...15

PC 1

Welding torch

Yes

P1...15

PC 2

Welding torch

Yes

P1...15

1) in case of correction mode, refer to Special parameters "P7 – correction mode, limit value setting"

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Example 1: Welding workpieces with different sheet metal thicknesses (non-latched)

Figure 5-51

Example 2: Welding different positions on a workpiece (latched)

Figure 5-52

Example 3: Aluminium welding of different sheet metal thicknesses (non-latched or latched special)

Figure 5-53

Up to 16 programs (PA0 to P

A15

) can be defined.

An operating point (wire speed, arc length correction, dynamics/choke effect) can be defined permanently in each program.

Program P0 is an exception: the settings for operating points are made manually here. Changes to the welding parameters are saved immediately!

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5.3.12.1 Selecting parameters (program A)

Changes to the welding parameters can only be made when the key switch is in position "1".

Figure 5-54

Select program number.

5.3.13 MIG/MAG automatic cut-out

The welding machine ends the ignition process or the welding process with an

• ignition fault (no welding current flows within 5 s after the start signal)

• arc interruption (arc is intrerrupted for longer than 5 s)

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5.3.14 Standard MIG/MAG torch

The MIG welding torch trigger is essentially used to start and stop the welding process.

Operating elements

Functions

Torch trigger

• Start/stop welding

Other functions are also possible by tapping the torch trigger, depending on the machine type and control configuration > see 5.10 chapter:

• Change over between welding programs (P8).

• Program selection before starting welding (P17).

• Change over between pulse and standard welding in the special latched operating mode.

• Switching between wire feed units in dual operation mode (P10).

5.3.15 MIG/MAG special-torches

Function specifications and more indepth information can be found in the operating manual for the relevant welding torch!

5.3.15.1 Program- and Up / down operation

Figure 5-55

Item

Symbol

Description 0

1 Welding torch function changeover switch (special welding torch required)

----

Changing over programs or JOBs

----

Infinite adjustment of welding performance.

5.3.15.2 Switching between Push/Pull and intermediate drive

WARNING

Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by

specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference.

• Appoint only skilled persons for repair work (trained service personnel)!

Test! Before re-commissioning, it is essential that an "inspection and test during operation" is carried

out conforming to IEC / DIN EN 60974-4 "Arc welding devices - inspection and testing during operation"!

• For detailed instructions, please see the standard operating instructions for the welding

machine.

The plugs are located directly on the M3.7x printed circuit board.

Plug

Function

on X24

Operation with Push/Pull welding torch (factory setting)

on X23

Operation with intermediate drive

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5.3.16 Expert menu (MIG/MAG)

The expert menu includes functions and parameters which are either not set on the machine control, or which do not require regular setting.

5.3.16.1 Selection

ENTER (Enter the menu)

• Keep the "welding parameters" push-button pressed for 3 s. NAVIGATION (Navigate the menu)

• Select parameters by pressing the "welding parameters" push-button.

• Set or change the parameters by turning the "welding parameter setting" rotary knob.

EXIT (Exit the menu)

• After 3 s, the machine will return automatically to the ready-to-operate status.

EXIT

ENTER

NAVIGATION

Figure 5-56

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Display

Setting/selection

Correct wire burn-back

If too high a value is set, a large ball will form at the tip of the wire electrode (bad reignition) or the wire electrode sticks to the contact tip. If too low a value is set, the wire electrode sticks to the weld pool.

• Increase value > increase wire burn-back

• Decrease value > decrease wire burn-back

Setting JOB-dependent program limit/n-cycle

The JOB-dependent program limit allows you to limit the number of programs that can be selected in the selected JOB to (2...9). This option can be set individually per JOB. In addition, a legacy option to set a "global program limit" is also available. To set this option use special parameter P4. This setting is then applied to all JOBs for which no JOB-dependent program limit has been set (see the special parameters description). You can also use the "Special latched (n-cycle)" operating mode if special parameter 8 is set to 2. In this case (JOB-dependent program switching activated, special parameter 8 = 2, special latched) you can switch to the next program by tapping the torch trigger in the main program (see the special parameters description).

1 ---------- No JOB-dependent program limit 2–9 ------- JOB-dependent program limit for max. selectable programs.

For machine versions with pulsed arc welding procedures only.

Change welding process (process switching)

With this function activated the welding process switches from standard arc welding to pulse arc welding. Switching is effected by either tapping the torch trigger (special latched) or by activating the superPuls function (switch between program PA and PB).

------- Function activated.

------- Function deactivated.

Pulse arc welding process (program P

START

)

The pulse arc welding process can be activated in the start program (P

START

) with the

special non-latched and special latched operating modes.

------- Function activated.

------- Function deactivated.

Pulse arc welding process (program P

END

)

The pulse arc welding process can be activated in the end program (P

END

) with the

special non-latched and special latched operating modes.

------- Function activated.

------- Function deactivated.

For machine versions with pulsed arc welding procedures only.

Ignition type (MIG/MAG)

Application: Low-spatter ignition, e.g. for aluminium and chrome/nickel materials. 0 = -------- Traditional arc ignition 1 = -------- Arc ignition with wire return for push/pull applications 2 = -------- Arc ignition with wire return for non-push/pull applications

Slope time (main current to secondary current)

Design and function

TIG welding

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5.4 TIG welding

5.4.1 Welding torch and workpiece line connection

Figure 5-57

Item

Symbol

Description 0

1 Welding torch 2 Welding torch hose package

3 Welding torch connection (Euro or Dinse torch connector)

Welding current, shielding gas and torch trigger integrated

Welding current cable, polarity selection

Welding current to the central connector/torch, enables polarity selection.

• TIG:

Connection socket for “-” welding current

Connection socket, "+" welding current

• TIG welding:

Workpiece connection

6 Workpiece

• Insert the central plug for the welding torch into the central connector and screw together with crown nut.

• Insert the cable plug on the work piece lead into the "+" welding current connection socket and lock by turning to the right.

• Welding current lead, insert polarity selection into the "-" welding current connection socket and lock.

If fitted:

Design and function

TIG welding

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5.4.2 Welding task selection

EXIT

Figure 5-58

5.4.3 Welding current setting

Figure 5-59

5.4.4 TIG arc ignition

5.4.4.1 Liftarc

Figure 5-60

The arc is ignited on contact with the workpiece:

a) Carefully place the torch gas nozzle and tungsten electrode 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 between the electrode

tip and the workpiece. The arc ignites and the welding current is increased, depending on the operating 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 or press the torch trigger depending on the operating mode selected.

Design and function

TIG welding

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5.4.5 Function sequences/operating modes

5.4.5.1 Explanation of signs and functions

Symbol

Meaning

Press torch trigger

Release torch trigger

Tap torch trigger (press briefly and release)

Shielding gas flowing

Welding output

Gas pre-flows

Gas post-flows Non-latched

Special, non-latched

Latched

Special, latched

Time

START

Ignition program

Main program

Reduced main program

END

End program

tS1

Slope duration from PSTART to PA

Design and function

TIG welding

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Non-latched mode

Figure 5-61

Selection

• Select non-latched operating 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.

• Arc is extinguished.

• Gas post-flow time elapses.

Special, non-latched

Figure 5-62

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 with pre-selected setting in start program “P

START

”.

• After the “tstart” ignition current time elapses, the welding current rises with the set upslope time “tS1”

to the main program “P

”.

Step 2

• Release torch trigger.

• The welding current reduces with the downslope time “tSe” to the end program “P

END

”.

• After the end current time “end” elapses, the arc will extinguish.

• Gas post-flow time elapses.

Design and function

TIG welding

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Latched mode

Figure 5-63

Selection

• Select latched operating 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 (no effect)

Step 3

• Press torch trigger (no effect)

Step 4

• Release torch trigger

• Arc is extinguished.

• Gas post-flow time elapses.

Design and function

TIG welding

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Latched special

Figure 5-64

Selection

• Select 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 at pre-selected setting in start program "P

START

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 t

START

elapses and at the

latest when the torch trigger is released. Tapping can be used to switch to the reduced main program "PB". Repeated tapping will switch

back to the main program "PA". Step 3

• Press the torch trigger.

• Slope to end program "P

END

Step 4

• Release torch trigger.

• Arc is extinguished.

• Gas post-flow time elapses.

5.4.6 TIG automatic cut-out

The welding machine ends the ignition process or the welding process with an

• ignition fault (no welding current flows within 5 s after the start signal)

• arc interruption (arc is intrerrupted for longer than 5 s)

Design and function

TIG welding

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5.4.7 TIG program sequence ("Program steps" mode)

Figure 5-65

Basic parameters

Item

Meaning/explanation

Setting range

Gas pre-flow time

0 s to 0.9 s

START

Ignition current

0% to 200%

Duration (start program)

0 s to 20 s

Slope duration from P

START

to PA

0 s to 20 s

PA (main program) Welding current, absolute

5 A to 550 A

Duration (PA)

0.01 s to 20.0 s

PB (reduced main program) Welding current

1% to 100%

Duration (reduced main program)

0.01 s to 20.0 s

Slope duration from PA to P

END

0 s to 20 s

END

(end program)

Welding current

1% to 100%

Duration (end program)

0 s to 20 s

Gas post-flow time

0 s to 20 s

superPuls

on/off

START

, PB, and P

END

are relative programs whose welding current settings are a percentage based on the

general welding current setting.

Design and function

MMA welding

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5.5 MMA welding

CAUTION

Risk of being crushed or burnt. When replacing spent or new stick electrodes

• Switch off machine at the main switch

• Wear appropriate safety gloves

• Use insulated tongs to remove spent stick electrodes or to move welded workpieces and

• Always put the electrode holder down on an insulated surface.

5.5.1 Connecting the electrode holder and workpiece lead

Figure 5-66

Item

Symbol

Description 0

1 Workpiece

Connection socket, "+" welding current

• MMA welding:

Workpiece connection

"-" welding current connection socket

• MMA welding:

electrode holder connection

4 Park socket, polarity selection plug

Retainer for the polarity selection plug in MMA mode or for transport.

5 Electrode holder

• Insert cable plug of the electrode holder into either the "+" or "-" welding current connection socket and lock by turning to the right.

• Insert cable plug of the workpiece lead into either the "+" or "-" welding current connection socket and lock by turning to the right.

• Insert the polarity selection plug in the park socket and lock in place by turning to the right.

Polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

Design and function

MMA welding

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5.5.2 Welding task selection

EXIT

Figure 5-67

5.5.3 Arcforce

Figure 5-68

Design and function

MMA welding

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5.5.4 Hotstart

The hotstart device improves the ignition of the stick electrodes using an increased ignition current.

a) = Hotstart time b) = Hotstart current I = Welding current t = Time

Figure 5-69

For hotstart parameter settings, > see 5.5.6 chapter

5.5.5 Antistick

Anti-stick prevents the electrode from annealing.

If the electrode 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 setting and correct according to the welding task!

Figure 5-70

5.5.6 Parameter overview

Figure 5-71

Basic parameters

Item

Meaning/explanation

Setting range

Welding current

5 A to maximum welding current

Hotstart time

0 to 20 s

Hotstart current

0 to 200 %

The hotstart current is a percentage based on the welding current selected.

Design and function

Remote control

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5.6 Remote control

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.

The remote controls are operated via the 19-pole remote control connection socket (analogue) or the 7-pole remote control connection socket (digital), depending on the model.

5.7 Interfaces for automation

WARNING

Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by

specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference.

• Appoint only skilled persons for repair work (trained service personnel)!

Damage to the machine due to improper connection! Unsuitable control leads or incorrect connection of input and output signals can cause damage

to the machine.

• Only use shielded control leads!

• If the machine is to be operated with control voltages connection via suitable isolation

amplifiers is required!

• To control the main or secondary current via control voltages, the relevant inputs must be enabled (see specification for activation of control voltage).

Design and function

Interfaces for automation

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5.7.1 Automation interface

These accessory components can be retrofitted as an option > see 9 chapter.

Input / output

Description

Diagram

Output

PE Connection for cable shielding

Output (open collector)

IGRO Current flows signal I>0 (maximum load 20

mA / 15 V) 0 V = welding current flows

E + R

Input

Not/Aus Emergency stop for higher level shut-down

of the power source. To use this function, jumper 1 must be unplugged on PCB M320/1 in the welding machine. Contact open  welding current off

Output

0 V Reference potential

G/P

Output

I>0 Power relay contact, galvanically isolated

(max. +/-15 V / 100 mA)

Output

Uist Welding voltage, measured against pin F,

0-10 V (0 V = 0 V; 10 V = 100 V)

Input

Str/Stp Start = 15 V / Stop = 0 V 1)

Output

+15 V Voltage supply (max. 75 mA)

Output

-15 V Voltage supply (max. 25 mA)

Output

0 V Reference potential

Output

Iist Welding current, measured on pin F;

0-10 V (0 V = 0 A, 10 V = 1000 A)

) The operating mode is given by the wire feed unit (the start / stop function equates to pressing

the torch trigger and is used in mechanised applications, for example).

Design and function

Interfaces for automation

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5.7.2 Remote control connection socket, 19-pole

Figure 5-72

Signal form

Short description

Output

Connection for PE cable screen

Output

Reference voltage for potentiometer 10 V (max. 10 mA)

Input

Control voltage specification (0 V–10 V) – wire feed speed

Output

Reference potential (0 V)

F/S

Input

Welding power start/stop (S1)

Input

Control voltage specification (0 V–10 V) – arc length correction

Input

Activation of control voltage specification for wire feed speed (S2) For activation, put signal to reference potential 0 V (pin E)

Input

Activation of control voltage specification for arc length correction (S3) For activation, put signal to reference potential 0 V (pin E)

U/V

Output

Supply voltage push/pull welding torch

Design and function

PC interface

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5.7.3 RINT X12 robot interface

The standard digital interface for mechanised applications (optional, retrofitting on the machine or external fitting by the customer)

Functions and signals:

• Digital inputs: start/stop, operating modes, JOB and program selection, inching, gas test

• Analogue inputs: control voltages, e.g. for welding performance, welding current, etc.

• Relay outputs: process signal, ready for welding, system composite fault, etc.

5.7.4 BUSINT X11 Industrial bus interface

The solution for easy integration with automated production with e.g.

• Profinet/Profibus

• EnthernetIP/DeviceNet

• EtherCAT

etc.

5.8 PC interface

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.

Equipment damage or faults may occur if the PC is connected incorrectly! Not using the SECINT X10USB interface results in equipment damage or faults in signal

transmission. The PC may be destroyed due to high frequency ignition pulses.

• Interface SECINT X10USB must be connected between the PC and the welding machine!

• The connection must only be made using the cables supplied (do not use any additional

extension cables)!

PC 300 welding parameter software

Create all welding parameters quickly on the PC and easily transfer them to one or more welding machines (accessories: set consisting of software, interface, connection leads).

Q-DOC 9000 welding data documentation software

(Accessories: set consisting of software, interface, connection leads) The ideal tool for welding data documentation of, for example:

welding voltage and current, wire speed and motor current.

WELDQAS welding data monitoring and documentation system

Network-compatible welding data monitoring and documentation system for digital machines

PC 300 welding parameter software

Create all welding parameters quickly on the PC and easily transfer them to one or more welding machines (accessories: set consisting of software, interface, connection leads).

Q-DOC 9000 welding data documentation software

(Accessories: set consisting of software, interface, connection leads) The ideal tool for welding data documentation of, for example:

welding voltage and current, wire speed and motor current.

WELDQAS welding data monitoring and documentation system

Network-compatible welding data monitoring and documentation system for digital machines

Design and function

Access control

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5.9 Access control

The key switch is only available for machines which are fitted with the "OW KL XX5" option ex works.

To protect against unauthorised or unintentional adjustment of the welding parameters on the machine, the control input can be locked with the aid of a key switch.

In key switch position 1 all functions and parameters can be set without restriction. In key switch position 0 the following functions and parameters cannot be changed:

• No adjustment of the operating point (welding performance) in programs 1–15.

• No change of welding or operating mode in programs 1–15.

• The welding parameters can be displayed but not changed in the control's function sequence.

• No welding task switching (JOB block operation P16 possible).

• No change of special parameters (except P10). Restart required.

5.10 Special parameters (advanced settings)

Special parameters (P1 to Pn) are applied for customer-specific configuration of machine functions. This allows the user maximum flexibility in optimising their requirements.

These settings are not configured directly on the machine control since a regular setting of the parameters is generally not required. The number of selectable special parameters can deviate between the machine controls used in the welding system (also see the relevant standard operating instructions).

If required, the special parameters can be reset to the factory settings > see 5.10.1.1 chapter.

Design and function

Special parameters (advanced settings)

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5.10.1 Selecting, changing and saving parameters

ENTER (Enter the menu)

• Switch off machine at the main switch.

• Press and hold the "left parameter selection" button and switch the machine on again at the

same time.

NAVIGATION (Navigate the menu)

• Select parameters by turning the "welding parameter setting" rotary dial.

• Set or change the parameters by turning the "arc length correction/select welding program"

rotary dial.

EXIT (Exit the menu)

• Press the "right parameter selection" button (switch machine off and on again).

ENTER

l0l

EXIT

NAVIGATION

Figure 5-73

Display

Setting/selection

Ramp time for wire inching

0 = -------- normal inching (10s ramp time) 1 = -------- fast inching (3s ramp time) (Ex works)

Block program "0"

0 = -------- P0 enabled (Ex works) 1 = -------- P0 blocked

Display mode for Up/Down welding torch with one-digit 7-segment display (two keys)

0 = -------- normal display (ex works) program number/welding power (0–9) 1 = -------- display toggles between program number/welding type

Program limitation

Programs 1 to max. 15 Ex works: 15

Special cycle in the special latched and non-latched operating modes

0 = -------- normal (previous) non-latched/latched (Ex works) 1 = -------- WF3 cycle for non-latched/latched

Design and function

Special parameters (advanced settings)

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Display

Setting/selection

Enable special jobs SP1 to SP3

0 = ------- no enabling (Ex works) 1 = ------- enabling of Sp1-3

Correction operation, threshold value setting

0 = ------- correction operation switched off (Ex works) 1 = ------- correction operation on

"Main program (PA)" flashing

Program changeover with standard torch

0 = ------- no program changeover (Ex works) 1 = ------- special latched 2 = ------- specific latched special (n cycle active)

Lat. and sp. lat. tapping start

0 = ------- no latched tapping start (Ex works) 1 = ------- latched tapping start possible

One or two-wire feed operation

0 = ------- single operation (Ex works) 1 = ------- dual operation, this unit is the "master" 2 = ------- dual operation, this unit is the "slave"

Special latched tapping time

0 = tapping function switched off 1 = 300ms (Ex works) 2 = 600ms

JOB list changeover

0 = ------- task-oriented JOB list 1 = ------- actual JOB list (Ex works) 2 = ------- actual JOB list, JOB changeover activated via accessories

Lower limit remote JOB changeover

Lowest JOB that can be selected using PowerControl 2 torches. Lower limit: 129 (Ex works)

Upper limit remote JOB changeover

JOB range of the POWERCONTROL2 torch Upper limit: 169 (Ex works)

HOLD function

0 = ------- HOLD values are not displayed 1 = ------- HOLD values are displayed (Ex works)

Block JOB mode

0 = ------- Block JOB mode not enabled (Ex works) 1 = ------- Block JOB mode enabled

Program selection with standard torch trigger

0 = ------- no program selection (Ex works) 1 = ------- program selection possible

Switching the operating mode and welding type using the wire feed control

0 = ------- Switching the operating mode and welding type using the wire feed control and

program 0 (factory setting).

1 = ------- Switching the operating mode and welding type using the wire feed control and

programs 0-15.

Mean value display for superPuls

0 = ------- Function switched off. 1 = ------- Function switched on (ex factory).

Design and function

Special parameters (advanced settings)

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Display

Setting/selection

Predefined pulse arc welding process in the PA program

0 = -------- Predefined pulse arc welding process in the PA program is disabled. 1 = -------- If the superPuls and welding process switching functions are available and

activated, the pulse arc welding process is always executed in the main program PA (ex factory).

Predefined absolute value for relative programs

Start program (P

START

), down-slope program (PB) and end program (P

END

) can be set

relative to the main program (PA) or in an absolute manner, as desired. 0 = -------- Relative parameter setting (ex factory) 1 = -------- Absolute parameter setting

Electronic gas flow control, type

1 = -------- type A (ex works) 0 = -------- type B

Program settings for relative programs

0 = -------- Combined setting of relative programs possible (ex works). 1 = -------- Individual setting of relative programs possible (ex works).

Correction or nominal voltage display

0 = -------- Correction voltage display (ex works). 1 = -------- Absolute nominal voltage display.

5.10.1.1 Reset to factory settings

All special parameters saved by the user will be overwritten by the factory settings!

l0l

Design and function

Special parameters (advanced settings)

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5.10.1.2 Special parameters in detail Ramp time for wire inching (P1)

The wire inching starts with a speed 1.0 m/min for 2 secs. It is subsequently increased to 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 parameter setting rotary dial. Changing the speed has no effect on the ramp time.

Program "0", releasing the program block (P2)

The program P0 (manual setting) is blocked. Only operation with P1-P15 is possible, irrespective of the key switch position.

Display mode for Up/Down welding torch with one-digit 7-segment display (P3) Normal display:

• Program mode: Program number

• Up/down operation: Welding power (0=minimum current/9=maximum current)

Toggling display:

• Program mode: Program number and welding procedure (P=pulse/n=not pulse) are toggled

• Up/down operation: Welding power (0=minimum current/9=maximum current) and symbol for up/down

operation are toggled

Program limit (P4)

Program selection can be limited with the special parameter P4.

• The setting is adopted for all JOBs.

• Program selection depends on the position of the "welding torch function" changeover switch

( > see 4.2.1 chapter).

Programs can only be switched when the changeover switch is in the "program" position.

• Programs can be switched by means of a connected remote control or special welding torch.

• If a special welding torch or a remote control is not connected, it is only possible to switch programs by

means of the "arc length correction/select welding program" rotary dial ( > see 4.3 chapter).

Special cycle in the operating modes special latched and non-latched (P5)

With the special sequence activated, the start of the welding process changes as follows:

Sequence for special non-latched mode/special latched mode:

• Start program "P

START

• Main program "PA"

Sequence for special non-latched mode/special latched mode with custom sequence activated:

• Start program "P

START

• Reduced main program "PB"

• Main program "PA"

Enabling special JOBs SP1 to SP3 (P6)

Phoenix Expert machine series: The welding task is set at the power source control; refer to the relevant system documentation.

If required, the predefined special welding tasks SP1 = JOB 129 / SP2 = JOB130 / SP3 = JOB 131 only can be selected at the wire feeder control. The special JOBs are selected by pressing the welding task selection push-button for a longer period. The special JOBs are switched by pressing the push-button briefly.

The JOB changeover is blocked if the key switch is in the “0” position. This block can be cancelled for the special JOBs (SP1 - SP3).

Design and function

Special parameters (advanced settings)

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Correction operation, threshold value setting (P7)

The correction operation is switched on and off for all JOBs and their programs at the same time. A correction operation is specified for wire speed (DV) and welding voltage correction (Ukorr) for each JOB. The correction value is saved separately for each program. The correction range can be maximum 30% of the wire speed and +/-9.9 V welding voltage.

Figure 5-74

Example for the operating point in correction mode:

The wire speed in one program (1 to 15) is set on 10.0 m/min. This corresponds to a welding voltage (U) of 21,9 V. When the key switch is set to "0" position, welding in

this program can only be carried out with these values. To allow the welder also to perform wire and voltage correction in program mode, the correction mode

must be switched on and limit values for wire and voltage must be specified. Setting of the correction limit value = WFlimit = 20% / Ulimit = 1.9 V Now the wire speed can be corrected by 20% (8.0 up to 12.0 m/min) and the welding voltage by +/-1.9 V

(3.8 V). In the example the wire speed is set on 11.0 m/min. This corresponds to a welding voltage of 22 V Now the welding voltage can be corrected by further 1.9 V (20.1 V and 23.9 V).

The values for voltage and wire-speed correction will be reset if the key switch is moved to the "1" setting.

Setting the correction range:

• Switch on the "Correction operation" special parameter (P7=1) and save the setting.

> see 5.11.1 chapter

• Key switch to position "1".

• Set correction range according to the following table:

Design and function

Special parameters (advanced settings)

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EXIT

Figure 5-75

• If the user is inactive for about 5 seconds, the pre-set values will be applied and the display switches back to the program display.

• Key switch back to position "0"!

Design and function

Special parameters (advanced settings)

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Switching programs with the standard torch trigger (P8) Special latched (latched absolute program sequence)

• Cycle 1: absolute program 1 is run

• Cycle 2: absolute program 2 is run after completion of "tstart".

• Cycle 3: absolute program 3 is run until the "t3" time has elapsed. The program then switches

automatically to absolute program 4.

Accessory components such as remote controls or special torches may not be connected! Program switching at the wire feed unit control is disabled.

Figure 5-76

Specific latched special (n cycle)

In the n cycle program sequence, the unit starts in the 1st cycle with start program P

start

from P

In the second cycle, the machine switches to absolute program 2, once the start time "tstart" has elapsed. Tapping switches to other programs (PA1 to max. PA9).

Figure 5-77

Design and function

Special parameters (advanced settings)

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The number of programs (PAn) corresponds to the cycle number specified under N cycle. 1st cycle

• Press and hold torch trigger.

• Shielding 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 is flowing (start

program P

START

from PA1)

2nd cycle

• Release torch trigger.

• Slope to main program PA1.

The slope to main program PA1 is given at the earliest after the set time t

START

elapses and at the latest when the torch trigger is released. Tapping (pressing briefly and releasing within 0.3 sec) can switch to other programs. Programs PA1 to P

are possible.

3rd cycle

• Press and hold torch trigger.

• Slope to end program P

END

from PAN. The program can be stopped at any time by pressing the torch

trigger longer than 0.3 sec. P

END

from PAN is then executed.

4th cycle

• Release torch trigger.

• WF motor stops.

• Arc is extinguished after the pre-selected wire burn-back time elapses.

• Gas post-flow time elapses.

Latched/special-latched tap start (P9)

In latched – tap start – operating mode it is possible to switch straight to the second step by tapping the torch trigger; it is not necessary for current to be flowing.

The welding can be halted by pressing the torch trigger for a second time.

Design and function

Special parameters (advanced settings)

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"Single or dual operation" (P10) setting

If the system is fitted with two wire feeds, no further accessory components may be operated on the 7-pole connection socket (digital)!

This relates to digital remote controls, robot interfaces, documentation interfaces, welding torches with digital control lead connection, etc.

No second wire feed may be connected in single operation (P10 = 0)!

• Remove connections to the second wire feed

In dual operation (P10 = 1 or 2), both wire feed units must be connected and configured differently on the controls for this operating mode!

• Configure one wire feed unit as the master (P10 = 1)

• Configure the other wire feed unit as a slave (P10 = 2)

Wire feed units with key switches (optional, > see 5.9 chapter) must be configured as masters (P10 = 1).

The wire feed configured as the master is active after the welding machine is switched on. There are no other functional differences between the wire feeds.

Latched special tapping time setting (P11)

The tapping time for changing over between the main program and reduced main program can be set in three levels.

0 = no tapping 1 = 320ms (factory setting) 2 = 640ms

JOB list switching (P12)

Value

Designation

Explanation

Task-oriented JOB list

The JOB numbers are sorted by welding wires and shielding gases. JOB numbers may be skipped during selection where relevant.

Actual JOB list

JOB numbers correspond to the actual memory cells. Each JOB can be selected; no memory cells are skipped during selection.

Actual JOB list, JOB changeover active

As for the actual JOB list. JOB changeover is also possible with accessory components, such as the PowerControl 2 torch.

Design and function

Special parameters (advanced settings)

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Creating user-defined JOB lists A consecutive memory range where accessories such as the POWERCONTROL 2 torch can be

used to switch between JOBs will be created.

• Set special parameter P12 to "2".

• Set "Program or Up/Down function" changeover switch to "Up/Down" position.

• Select an existing JOB which is closest to the required result.

• Copy JOB to one or more target JOB numbers.

If any JOB parameters need to be changed, select the target JOBs in sequence and change the parameters individually.

• Set special parameter P13 to the lower limit and

• Set special parameter P14 to the upper limit of the target JOBs.

• Set "Program or Up/Down function" changeover switch to "Program" position.

JOBs can be changed over in the specified range using the accessory component.

Copying JOBs, "Copy to" function The possible target range is between 129 - 169.

• First configure special parameter P12 to P12 = 2 or P12 = 1!

By repeating the last two steps, the same source JOB can be copied to multiple target JOBs. If the control does not register any user activity for longer than 5 seconds, the parameter display is shown

once more and the copy process is complete.

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