Abicor Binzel EWR Instructions for use

EWR Quick
Install Instructions
www.binzel-abicor.com
TECHNOLOGY FOR THE WELDER’S WORLD

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Binzel EWR Installation Overview
Power Connection
with Different
Adapter
Gas Supply Fix Shunt +/- Cable
Gas Connection
from EWR to Power
Source/Wire Feeder
STEP 1: Check Inventory of Package
1 2
4 5
Inventory Checklist
1. Warranty
2. Guarantee
3. Calibration Report
4. Safety Documentation
5. Operating Instructions
6. EWR or EWR Pro (Basic Model shown)
7. 110v AC Power Supply
8. Current Measuring Shunt*
*Confirm that the current capacity of the measuring shunt is
adequately sized for the welding operation that it will be used
for. Measuring shunts are available in 150, 300, & 500 amp
models.
3
6
7
8

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STEP 2: Mount the EWR Regulator
The EWR Regulator has the flexibility to be mounted wherever it makes the most sense for your
application. A few guidelines to consider:
■ The EWR should be mounted on a stable location away from welding sparks or places
where it can be damaged.
■ The current measuring cable, gas hoses, and power supply cable must have easy, bind-
free access to their respective connectors on the regulator.
■ Mounting location for optimum performance of EWR is between 6 to 30 feet behind the
solenoid on your wire feeder. Ideal location for robotic installations is on the pedestal at
the base of the robot. Semi-automatic and Manual applications can vary as noted. Refer
to Steps 5, 7, and 8 for additional information on hose lengths and tuning of system.
EWR Basic shown
STEP 3: Shunt Installation
■ Pass either the work or electrode cable through the shunt and affix the shunt onto a stable
location.
■ Route the shunt connection cable back to the EWR. Secure the shunt connection cable
utilizing non-conductive fasteners and ties. Ensure the shunt cable is not damaged. Do
not coil any excess cable.
■ Connect the shunt measuring cable to the EWR or EWR Pro regulator box.
Note: Do not have any part of the shunt cable in close proximity to or in contact with any
electrically charged cord, as this will give a false current signal to the regulator.

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STEP 4: Connect Gas Supply to EWR Regulator
STEP 5: Connecting Gas to Wire Feeder
■ Remove any gas flow limiting orifices, regulator,
or regulator flowmeters from the incoming gas
source line.
■ Ensure gas source delivery pressure is no less than
35 PSI and no more than 65 PSI.
■ Connect hose from the supply line to left gas barb
on the EWR Regulator.
EWR Pro shown
Attach Gas Supply Line to Regulator here
■ Attach one end of the gas hose to the right gas barb of the regulator.
■ Route the gas hose to the feeder to ensure that the hose will not be exposed to pinching,
binding, or damage. Ensure hose is of sufficient length for the robot’s entire range of
motion.
■ Connect hose to the wire feeder’s gas supply fitting.
■ Optimal hose length is considered 1 foot longer than the torch length with a minimum of
6 feet. For instance, if the torch is 7 feet, then the gas hose between the EWR and the
feeder should be no less than 8 feet.
EWR Pro shown
Wire Feeder
Gas to Wire Feeder Connection

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STEP 6: Connect EWR to Electrical Power
■ Connect one end of the AC Power adapter to the power supply connector on the right
side of the regulator.
■ Connect the AC Power adapter to a suitable outlet.
■ Secure excess cable so as not to create a trip hazard.
EWR Pro shown
AC Power adapter connection
STEP 7: EWR Initialization
Gas Flow Schedules
The EWR offers you the ability to select the most efficient gas delivery schedule for your
application. There are a total of 11 schedules on the EWR and EWR Pro. Selection is done
by simply pressing either the plus (+) or minus (-) buttons. The factory default setting is right
in the middle of these schedules and serves as a starting point for the majority of welding
applications. There are five schedules that provide a greater volume of delivery than the
factory default and five schedules that provide less volume than the factory default.
The illuminated yellow LED at 14 is an indication that
the default setting is the schedule that is being used. The
factory default schedule provides a flow of 14L/Min
(or 29.7 CFH) at 15 to 90 amperes of welding current,
ramping up to a flow rate of 21 L/Min (44.5 CFH) at
300 amperes. Note: for reference, conversion to CFH
from L/Min is 2.12:1 (e.g. 20 L/Min = 42.4 CFH)
The green LED indicates that the minus (-) button has
been pushed, changing the schedule so that 13 L/
MIN (27.6 CFH) will be delivered at 15 to 90 amperes
(versus 14L/Min on the default setting). The flow will ramp up to 20L/Min at 300 amperes
(versus 21 L/Min on default).
See chart on back cover for gas flow schedules in relation to ampere usage.

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STEP 7: EWR Initialization (Cont.)
Setting the Gas Flow
Begin with the default setting (yellow LED displayed at 14) and complete weld. If the weld is
not acceptable due to porosity, unstable arc, etc., continue to Troubleshooting. If the weld is
acceptable, continue with the following procedure:
■ Press the minus (-) button once and repeat.
■ Continue with this process, moving towards a schedule with less flow, until the weld
exhibits excessive spatter, instability, and/or porosity.
■ At this point, press the plus (+) button once.
■ Complete another weld and verify that this setting is acceptable. If so, move on to Step 8.
Troubleshooting
■ Press the plus button (+) once and repeat the weld. If the weld is acceptable, this
procedure is completed and you can move on to Step 8.
■ If the weld still is not acceptable, repeat the procedure until an acceptable weld is
achieved, then move on to Step 8.
STEP 8: Setting the Gas Flow Pressure
What is this Adjustment?
The gas pressure between the EWR and the closed magnetic valve in the power source or
feeder can be adjusted. This adjustment is necessary if you have longer cable assemblies or
other circumstances which might affect a proper gas flow. The factory default setting is 0.6bar
(8.7 PSI) outgoing pressure. The pressure can be changed from 0.2bar – 2.0bar (2.9 PSI –
29 PSI).
BINZEL Recommendations for MIG/MAG
Length of Cable Assembly Recommended RMA Gas Flow Pressures
Under 8m (26 feet) 0.4 - 0.6bar (5.8 - 8.7 PSI)
9 - 18m (29 - 59 feet) 0.8 - 1.0bar (11.6 -14.5 PSI)
19 40m (62 - 131 feet) 1.2 - 1.4bar (17.4 - 20.3 PSI)
Longer than 41m (134 feet) 1.6 - 2.0bar (23.2 - 29 PSI)

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Setting the Gas Flow Pressure
1. Disconnect Power Supply 2. Reconnect power supply while pressing the ON/OFF
button. The EWR is now in setup mode for pressure.
3. Press the plus (+) or (-) button to adjust the outgoing
pressure. The first illuminated LED indicates that the
EWR is in pressure mode. Each additional illuminated
LED represents 0.2bar of pressure; i.e. 3 LEDs =
0.4bar, 6 LEDs = 1.0bar, or 11 LEDs = 2.0bar.
4. Press and hold the ON/OFF button until the lights
make a quick flash. The flash confirms the new setting
is saved, and the EWR returns to normal mode of
operation.
APPENDIX: BINZEL EWR Part Numbers
Part Number Items and Description
514.1005 Measuring Shunt 150A 1.5m for EWR Basic/PRO
514.1006 Measuring Shunt 300A 3m for EWR Basic/PRO
514.1007 Measuring Shunt 500A 5m for EWR Basic/PRO
514.1008 Holder for EWR Basic/PRO/TIG
514.1009 Transport Case for Welding Monitor
514.1019 EWR Basic Complete Package (500A/5m)
514.1020 EWR PRO Complete Package (500A/5m)
514.0143 EWR Splitter for EWR PRO (MIG/MAG)

www.binzel-abicor.com
TECHNOLOGY FOR THE WELDER’S WORLD
Alexander Binzel Corporation
650 Medimmune Court, Suite 110
Frederick, MD 21703
Phone: [phone]
Fax: [phone]
Email: [email protected]
Gas Flow Rate in Relation to EWR Setting (L/Min)
Ampere Usage
Gas Flow Measurement Chart for the EWR
INT.9039 • 06.16 • © 2016 Alexander Binzel Corporation • Printed USA