EWM R50 7POL User manual

Operatinginstructions
EN
Remote control
R50 7POL
099-008776-EW501
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21.01.2016
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General instructions
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read the operating instructions for all system components!
•Observe accidentprevention regulations!
•Observe all local regulations!
•Confirm with a signature where appropriate.
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 [phone].
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 arisingfrom incorrectinstallation, improper operation or incorrectusage and maintenance
or any actions connected to this in any way.
© EWMAG · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, 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, errorsexcepted.

Contents
Notes on the use of these operating instructions
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1 Contents
1Contents.......................................................................................................................................3
2Safety instructions.......................................................................................................................4
2.1 Notes on the use of these operating instructions.....................................................................4
2.2 Explanation of icons..............................................................................................................5
2.3 General................................................................................................................................6
2.4 Transport .............................................................................................................................8
2.5 Scope of delivery..................................................................................................................8
2.5.1 Ambient conditions.................................................................................................8
2.5.1.1 In operation .............................................................................................8
2.5.1.2 Transport and storage ..............................................................................8
3Intended use ................................................................................................................................9
3.1 Use and operation solely with the following machines .............................................................9
3.2 Documents which also apply .................................................................................................9
3.2.1 Warranty................................................................................................................9
3.2.2 Declaration of Conformity........................................................................................9
3.2.3 Service documents (spare parts) .............................................................................9
4Machine description –quick overview .......................................................................................10
4.1 Front view..........................................................................................................................10
4.2 Rear view...........................................................................................................................11
4.3 Machine control –Operating elements.................................................................................12
4.3.1 Machine control –Concealed operating elements...................................................14
5Design and function...................................................................................................................16
5.1 General..............................................................................................................................16
5.2 Establishing the connections ...............................................................................................16
5.3 Welding task selection ........................................................................................................16
5.4Organise welding task (JOB)...............................................................................................17
5.4.1 Load welding task (JOB) from welding machine to remote control............................17
5.4.2 Copy welding task (JOB) from remote control to welding machine ...........................18
5.4.3 Delete saved welding task (JOB) in remote control.................................................19
5.5 Special parameters (advanced settings)...............................................................................20
5.5.1 Selecting, changing and saving parameters ...........................................................20
5.5.1.1 Special parameters in detail....................................................................21
5.5.1.2 Reset to factory settings .........................................................................22
5.6 Protective flap, welding machine control...............................................................................23
6Maintenance, care and disposal.................................................................................................24
6.1 General..............................................................................................................................24
6.2 Maintenance work, intervals ................................................................................................24
6.2.1 Monthly maintenance tasks...................................................................................24
6.3 Disposing of equipment.......................................................................................................25
6.3.1 Manufacturer's declaration to the end user.............................................................25
6.4 Meeting the requirements of RoHS......................................................................................25
7Technical data............................................................................................................................26
7.1 R50 7POL..........................................................................................................................26
8Accessories ...............................................................................................................................27
8.1 Connection and extension cables ........................................................................................27
9Appendix A ................................................................................................................................28
9.1 Overview of EWM branches................................................................................................28

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.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
or destroying the product.
•The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
•The hazard is explained using a symbol at the edge of the page.
Special technical points which users must observe.
Instructions and lists detailing step-by-step actions for given situations canbe 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
Special technical points which users must observe.
Correct
Wrong
Press
Do not press
Press and keep pressed
Turn
Switch
Switch off machine
Switch on machine
ENTER
enter the menu
NAVIGATION
Navigating in the menu
EXIT
Exit the menu
4 s
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use

Safety instructions
General
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2.3 General
DANGER
Electric shock!
Welding machines use high voltages which can result in potentially fatal electric shocks
and burns on contact. Even low voltages can cause you to get a shock and lead to
accidents.
•Do not touch any live parts in or on the machine!
•Connection cables and leads must be free of faults!
•Switching off alone is not sufficient!
•Place welding torch and stick electrode holder on an insulated surface!
•The unit should only be opened by specialist staff after the mains plug has been
unplugged!
•Only wear dryprotective clothing!
•Waitfor 4 minutes until the capacitors have discharged!
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 Maintenance, care and disposal chapter!
•Unwind welding leads completely!
•Shield devices or equipment sensitive to radiation accordingly!
•The correctfunctioning of pacemakers may be affected (obtain advice froma doctor if
necessary).
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!
Validity of the document!
This document is valid only in combination with the operating instructions for the
product being used!
•Read and observe the operating instructions for all system components, especially the
safety instructions!
Fire hazard!
Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts
and hot slag produced during the welding process.
Stray welding currents can also result in flames forming!
•Check for fire hazards in the working area!
•Do not carryany easily flammable objects such as matches or lighters.
•Keep appropriate fire extinguishing equipment to hand inthe working area!
•Thoroughly remove any residue of flammable substances from the workpiece before
starting welding.
•Only continue work on welded workpieces once they have cooled down.
Do not allow to come into contact with flammable material!
•Connect welding leads correctly!

Safety instructions
General
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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)!
•Weardry protective clothing (e.g. welding shield, gloves, etc.) accordingto 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!
Hazards due to improper usage!
Hazardsmay 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 proper usage and by trained or expert staff!
•Do not modify or convert the equipment improperly!
CAUTION
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
•Wearsuitable ear protection!
•Persons located within the working area must wear suitable ear protection!
CAUTION
Obligations of the operator!
The respective national directives and laws must be observed for operation of the
machine!
•National implementation of the framework directive (89/391/EWG), as well as the
associated individual directives.
•In particular, directive (89/655/EWG), on the minimum regulations for safety and health
protection when staff members use equipment during work.
•The regulations regarding work safety and accidentprevention for the respective country.
•Setting up and operating the machine accordingto IEC 60974-9.
•Check at regular intervals that users are working in a safety-consciousway.
•Regular checksof the machine accordingto IEC 60974-4.
Damage due to the use of non-genuine parts!
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 isswitched off.
Trained personnel!
Commissioning is reserved for persons who have the relevant expertise of working with
arc welding machines.

Safety instructions
Transport
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2.4 Transport
CAUTION
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
•Disconnect supply lines!
2.5 Scope of delivery
The delivery is checked and packaged carefully before dispatch, however it is not possible to exclude the
possibility of damage during transit.
Receiving inspection
•Check that the delivery is complete using the delivery note!
In the event of damage to the packaging
•Check the delivery for damage (visual inspection)!
In the event of complaints
If the delivery has been damaged during transport:
•Please contact the last haulier immediately!
•Keep the packaging (for possible checking by the haulier or for the return shipment).
Packaging for returns
If possible, please use the original packaging and the original packaging material. If youhave any queries
on packaging and protection during transport, please contact your supplier.
2.5.1 Ambient conditions
CAUTION
Equipment damage due to dirt accumulation!
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)!
2.5.1.1 In operation
Temperature range of the ambient air:
•-25 °C to +40 °C
Relative air humidity:
•Up to 50% at 40 °C
•Up to 90% at 20 °C
2.5.1.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
•-30 °C to +70 °C
Relative air humidity
•Up to 90% at 20 °C

Intendeduse
Use and operation solely with the following machines
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3 Intended use
WARNING
Hazards due to improper usage!
Hazardsmay 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 proper usage and by trained or expert staff!
•Do not modify or convert the equipment improperly!
Remote control for welding machine and accessory functions.
3.1 Use and operation solely with the followingmachines
•Phoenix Progress / Expert
•alpha Q
•Taurus Synergic S
3.2 Documents which also apply
3.2.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.2.2 Declaration of Conformity
The designated machine conforms to EC Directives and standards in terms of its design
and construction:
•EC Low Voltage Directive (2006/95/EC),
•EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised modifications, improperly
conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted
conversion work not specifically authorised by the manufacturer.
The original copy of the declaration of conformity is enclosed with the unit.
3.2.3 Service documents (spare parts)
DANGER
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)!
Spare parts canbe obtained fromthe relevant authorised dealer.

Machine description –quickoverview
Front view
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4 Machine description – quick overview
4.1 Front view
Figure 4-1
Item
Symbol
Description 0
1
Lid
2
Machine control- See 4.3 Machine control –Operating elements chapter
3
Protective cap
4
Connection socket, 7-pole (digital)
Connection to the digital remote control connection on power source or wire feed unit.

Machine description –quickoverview
Rear view
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4.2 Rear view
Figure 4-2
Item
Symbol
Description 0
1
Holder for suspending the remote control
2
Carrying handle
3
Machine feet
4
Fixing magnet
To mount remote control on magnetisable surfaces

Machine description –quickoverview
Machine control –Operating elements
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4.3 Machine control –Operating elements
Figure 4-3

Machine description –quickoverview
Machine control –Operating elements
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Item
Symbol
Description 0
1
Lid - See 4.3.1 Machine control –Concealed operating elements chapter
2
Display, left
Welding current, material thickness, wire speed, hold values
3
Push-button, parameter selection left/power-saving mode
AMP Welding current
Material thickness
Wirefeed 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.
4
Display, JOB
Shows the currently selected welding task (JOB number).
5
Welding parameter setting, rotary dial
For setting the welding performance, for selecting the JOB (welding task) and for
setting other welding parameters.
6
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
7
Display, right
Welding voltage, programnumber, motor current (wire feed mechanism)
8
Button, Parameter selection (right)
VOLT Welding voltage
Prog Program number
kW Welding performance display
Gas flow quantity (optional)
9
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).
10
Push-button, throttling effect (arc dynamics)
Arc is harder and more narrow
Arc is softer and wider
11
Welding type push-button
Standard arc welding
Pulsed arc welding

Machine description –quickoverview
Machine control –Operating elements
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4.3.1 Machine control –Concealed operating elements
Figure 4-4
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 (PSTART)
•Wirespeed:1% to 200% of the main program PA
•Correctionof the arc length -9.9V to +9.9 V
4
sec
Signal light, start time
Setting range, absolute 0.0 s to 20.0 s (0.1 s increments)
5
sec
Signal light, slope time program PSTART to main program PA
Setting range 0.0 s to 20.0 s (0.1 s increments)
6
Signal light, main program (PA)
•Wirespeed WF-min.to WF-max.
•Correctionof the arc length -9.9V to +9.9 V
7
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)
•Wirespeed:1% to 200% of the main program PA
•Correctionof the arc length -9.9V to +9.9 V
9
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.
10
sec
Signal light, slope time program PA(or PB)to end program PEND
Setting range 0.0 s to 20.0 s (0.1 s increments)
11
Signal light, end program (PEND)
•Wirespeed:1% to 200% of the main program PA
•Correctionof the arc length -9.9V to +9.9 V
12
sec
Signal light, duration of end program PEND
Setting range 0.0 s to 20.0 s (0.1 s increments)
13
Signal light, gas post-flow time
Setting range 0.0 s to 20.0 s

Machine description –quickoverview
Machine control –Operating elements
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Item
Symbol
Description 0
14
Super-
puls
Signal lamp, super pulse function
Lights up when the super pulse function is active.
15
Signal light: organising welding tasks (JOB)
Flashes when JOB number is displayed or selected
16
Press organise welding tasks (JOB) push-button
Briefly pressing the button = display of welding task selected in welding system
Holding the button down for long (> 3 s) = "Organise welding tasks (JOB)" mode:
•Load welding task (JOB) from welding machine to remote control
•Copy welding task (JOB) from remote control to welding machine
17
Push-button, wire inching/motor current (wire feed mechanism)
18
Gas test / rinse button
•Gas test: For setting the shielding gas quantity
•Rinse: For rinsinglonger hose packages

Design and function
General
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5 Design and function
5.1 General
The remote control is virtually a 100% copy of the existing welding machine/wire feed unit control. Users
can optimise all process parameters required for the welding task either directly at the work site or, as
usual, on the welding machine/wire feed unit control.
Basically, all descriptions on the process settings in the standard operating instructions shall
apply. This operating manual exclusively describes deviating control functions.
5.2 Establishingthe connections
CAUTION
Damage to the machine due to improper connection!
The remote controls have been developed to be connected to welding machines or wire
feed units only. Connecting them to other machines may cause damage to the
machines!
•Observe the operating instructions for the welding machine or wire feed unit!
•Switch off the welding machine before connecting!
Observe documentation of other system components when connecting!
•Switch off the welding machine.
•Insert the male connector plug (socket) into the remote control connection socket and lock by turning
to the right.
•Insert the male connector plug (pin) into the remote control connection socket of the welding machine
and lock by turning to the right.
5.3 Welding task selection
The remote control can show the selected JOB in the display. It, however, cannot change the JOB.
The welding task (JOB) canonly be selected on the machine control of the welding machine/wire feed
unit (also see chapter "Selection of welding tasks" in the standard operating instructions).

Design and function
Organise welding task (JOB)
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5.4 Organise weldingtask (JOB)
The remote control is equipped with a data storage medium (Flash ROM). Users can download any
welding task (JOB) onto this memory fromthe memory of the welding machine. This JOB can
subsequently be copied via an existing JOB in the free memory of the welding machine (JOB 129 -
JOB 169) or onto itself. Likewise, it is also possible to copy this JOB to other welding systems that have
been approved for this remote control. The unit will once again return to the main menu if the user does
not make any entry within 10 seconds.
5.4.1 Load welding task (JOB) from welding machine to remote control
3 s
3 s
1
3
4
5
2
Figure 5-1
Item
Symbol
Description 0
1
Press organise welding tasks (JOB) push-button for at least 3 sec
The remote control switches to the "Organise welding tasks (JOB)" mode.
2
Select function:
Load welding task (JOB).
3
JOB selection
Select any JOB for loading.
4
Press organise welding tasks (JOB) push-button for at least 3 sec
JOB is loaded into remote control memory.
5
JOB will be loaded
The system returns to the main menu following completion of the loading process.

Design and function
Organise welding task (JOB)
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5.4.2 Copy welding task (JOB) from remote control to welding machine
A JOB must first be loaded onto the remote control before it can be copied (also see chapter
"Loading the welding task (JOB) from the welding machine to the remote control"). The loaded
JOB can subsequently be copied onto itself or to a storage location in the free space of the
power source (JOB 129 - JOB 169).
3 s
3 s
3
4
5
6
7
2
1
Figure 5-2

Design and function
Organise welding task (JOB)
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Item
Symbol
Description 0
1
Press organise welding tasks (JOB) push-button for at least 3 sec
The remote control switches to the "Organise welding tasks (JOB)" mode.
2
Select function:
Copy welding task (JOB)
3
Display of JOB saved in the remote control
Example: JOB 129
4
Press organise welding tasks (JOB) push-button
The remote control switches to the target selection of the JOB to be overwritten in the
welding machine.
5
Selection of the JOB to be overwritten in the welding machine
The JOB loaded in the remote control memory can be copied via an existing JOB in the
freememory of the welding machine (JOB 129 - JOB 169) or onto itself.
6
Press organise welding tasks (JOB) push-button for at least 3 sec
The copy process is started.
7
JOB is being copied
Following completion of the copyingprocess, the program returns to the main menu.
5.4.3 Delete saved welding task (JOB) in remote control
All special parameters will be overwritten by the factory settings!
The welding task (JOB) will be deleted in the remote control memory.
Operating
element
Action
Result
Display
left
right
Switch off the welding machine
-
Press and hold the "right parameter selection"
push-button on remote control
-
Switch on the welding machine
Release push-button
Waitfor about 3 seconds
Switch off the welding machine and restart in
order to implement the changes
-

Design and function
Special parameters (advanced settings)
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5.5 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 candeviate 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 5.5.1.2 Reset to factory
settings chapter.
5.5.1 Selecting, changing and saving parameters
ENTER (Enter the menu)
•Switch off the machine at the main switch.
•Press and hold the "left parameter selection" button on the remote control and, at the same
time, switch on the machine.
NAVIGATION (Navigate the menu)
•Select parameters by turning the "welding parameter setting" rotary dial.
•Set or change 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
+
EXIT
HOLD
AMP
VOLT
PROG
NAVIGATION
m/min
l
0
Figure 5-3
Display
Setting/selection
Block program "0"
0 = P0 enabled (Ex works)
1 = P0 blocked
Program limitation
Programs 1 to max. 15
Ex works: 15
HOLD function
0 = HOLD values are not displayed
1 = HOLD values are displayed (Exworks)
Mean value display for superPuls
0 = Function switched off.
1 = Function switched on (ex factory).
Program settings for relative programs
0 = Combined setting of relative programs possible (ex works).
1 = Individual setting of relative programs possible (ex works).