EWM alpha Q 330 Progress puls MM TKM User manual

Operating instructions
EN
Welding machine
alpha Q 330 Progress puls HP MM TKM
099-005402-EW501
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24.11.2016
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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 [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 arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG
Dr. Günter-Henle-Straße 8
56271 Mündersbach
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
1Contents..................................................................................................................................................3
2For your safety.......................................................................................................................................6
2.1 Notes on the use of these operating instructions ..........................................................................6
2.2 Explanation of icons.......................................................................................................................7
2.3 Part of the complete documentation..............................................................................................8
2.4 Safety instructions..........................................................................................................................9
2.5 Transport and installation ............................................................................................................13
3Intended use.........................................................................................................................................14
3.1 Applications..................................................................................................................................14
3.2 Documents which also apply.......................................................................................................15
3.2.1 Warranty.......................................................................................................................15
3.2.2 Declaration of Conformity.............................................................................................15
3.2.3 Welding in environments with increased electrical hazards.........................................15
3.2.4 Service documents (spare parts and circuit diagrams)................................................15
3.2.5 Calibration/Validation ...................................................................................................15
4Machine description –quick overview ..............................................................................................16
4.1 Front view ....................................................................................................................................16
4.2 Rear view.....................................................................................................................................18
4.3 Inside view...................................................................................................................................20
4.4 Machine control –Operating elements........................................................................................22
4.4.1 Functional sequence ....................................................................................................24
5Design and function.............................................................................................................................25
5.1 Transport and installation ............................................................................................................25
5.1.1 Ambient conditions.......................................................................................................25
5.1.1.1 In operation...................................................................................................25
5.1.1.2 Transport and storage...................................................................................25
5.1.2 Machine cooling............................................................................................................26
5.1.3 Workpiece lead, general...............................................................................................26
5.1.4 Welding torch cooling system.......................................................................................26
5.1.4.1 Cooling module connection...........................................................................26
5.1.5 Notes on the installation of welding current leads........................................................27
5.1.5.1 Stray welding currents...................................................................................28
5.1.6 Mains connection..........................................................................................................29
5.1.6.1 Mains configuration.......................................................................................29
5.1.7 Shielding gas supply (shielding gas cylinder for welding machine).............................30
5.1.7.1 Pressure regulator connection......................................................................30
5.1.7.2 Shielding gas hose connection.....................................................................31
5.1.8 Shielding gas volume settings......................................................................................32
5.1.8.1 Gas test.........................................................................................................32
5.1.8.2 Purge hose package.....................................................................................32
5.2Welding data display....................................................................................................................33
5.3 MIG/MAG welding........................................................................................................................34
5.3.1 Welding torch connection.............................................................................................34
5.3.2 Connection for workpiece lead.....................................................................................36
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 Burn-back......................................................................................................44
5.3.5.4 superPuls......................................................................................................45

Contents
Notes on the use of these operating instructions
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5.3.6 MIG/MAG operating point.............................................................................................46
5.3.6.1 Operating point setting via welding current, material thickness or wire
feed speed.....................................................................................................46
5.3.6.2 Arc length correction setting..........................................................................47
5.3.6.3 Accessory components for operating point setting.......................................47
5.3.6.4 coldArc / coldArc puls....................................................................................48
5.3.6.5 forceArc / forceArc puls.................................................................................49
5.3.6.6 rootArc/rootArc puls.......................................................................................50
5.3.6.7 pipeSolution...................................................................................................50
5.3.7 MIG/MAG functional sequences / operating modes.....................................................51
5.3.7.1 Explanation of signs and functions................................................................51
5.3.8 MIG/MAG program sequence ("Program steps" mode)...............................................64
5.3.8.1 Selection of the program sequence parameter.............................................64
5.3.8.2 MIG/MAG overview of parameters................................................................65
5.3.8.3 Example, tack welding (non-latched)............................................................66
5.3.8.4 Example, aluminium tack welding (non-latched special) ..............................66
5.3.8.5 Example, aluminium welding (latched special).............................................67
5.3.8.6 Example, visible seams (latched super pulse)..............................................68
5.3.9 Conventional MIG/MAG Welding (GMAW non synergic).............................................69
5.3.9.1 Setting the operating point (welding output)..................................................69
5.3.10 Main program A mode..................................................................................................70
5.3.10.1 Selecting parameters (program A)................................................................72
5.3.11 MIG/MAG automatic cut-out.........................................................................................72
5.3.12 Standard MIG/MAG torch.............................................................................................73
5.3.13 MIG/MAG special-torches.............................................................................................73
5.3.13.1 Program and up/down operation...................................................................73
5.3.13.2 Switching between Push/Pull and intermediate drive...................................74
5.3.14 Expert menu (MIG/MAG)..............................................................................................75
5.3.14.1 Selection........................................................................................................75
5.4 TIG welding..................................................................................................................................77
5.4.1 Welding torch and workpiece line connection..............................................................77
5.4.2 Welding task selection..................................................................................................78
5.4.2.1 Welding current setting..................................................................................78
5.4.3 TIG arc ignition .............................................................................................................79
5.4.3.1 Liftarc.............................................................................................................79
5.4.4 Function sequences/operating modes..........................................................................79
5.4.4.1 Explanation of signs and functions................................................................79
5.4.4.2 TIG automatic cut-out....................................................................................82
5.4.5 TIG program sequence ("Program steps" mode).........................................................83
5.5 MMA welding................................................................................................................................84
5.5.1 Connecting the electrode holder and workpiece lead ..................................................84
5.5.2 Welding task selection..................................................................................................85
5.5.2.1 Welding current setting..................................................................................85
5.5.2.2 Arcforce.........................................................................................................86
5.5.2.3 Hotstart..........................................................................................................86
5.5.2.4 Antistick.........................................................................................................86
5.5.3 Parameter overview......................................................................................................87
5.6 Access control..............................................................................................................................88
5.7 Remote control.............................................................................................................................88
5.8 Power-saving mode (Standby).....................................................................................................88
5.9 Interfaces for automation .............................................................................................................89
5.9.1 Automation interface.....................................................................................................89
5.9.2 Remote control connection socket, 19-pole .................................................................90
5.9.3 RINT X12 robot interface..............................................................................................91
5.9.4 BUSINT X11 Industrial bus interface............................................................................91
5.10 PC interface .................................................................................................................................91
5.11 Special parameters (advanced settings)......................................................................................92
5.11.1 Selecting, changing and saving parameters.................................................................92
5.11.1.1 Reset to factory settings................................................................................94
5.11.1.2 Special parameters in detail..........................................................................95

Contents
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5.12 Machine configuration menu......................................................................................................103
5.12.1 Selecting, changing and saving parameters..............................................................103
5.12.2 Aligning the cable resistance......................................................................................105
6Maintenance, care and disposal.......................................................................................................107
6.1 General......................................................................................................................................107
6.2 Cleaning.....................................................................................................................................107
6.3 Maintenance work, intervals......................................................................................................108
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
7Rectifying 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
8Technical data ....................................................................................................................................116
8.1 alpha Q 330 ...............................................................................................................................116
9Accessories........................................................................................................................................117
9.1 General accessories..................................................................................................................117
9.2 Options.......................................................................................................................................117
9.3 Computer communication..........................................................................................................117
9.4 Remote control/connecting and extension cable.......................................................................118
9.4.1 7-pole connection.......................................................................................................118
9.4.2 19-pole connection.....................................................................................................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

For your safety
Notes on the use of these operating instructions
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2 For your safety
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.

For your safety
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

For your safety
Part of the complete documentation
8
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2.3 Part of the complete documentation
These operating instructions are part of the complete documentation and valid only in
combination with all other parts of these instructions! Read and observe the operating
instructions for all system components, especially the safety instructions!
The illustration shows a general example of a welding system.
Figure 2-1
Item
Documentation
A.1
Remote control
A.2
Transport cart
A.3
Remote control
A.4
Power source
A.5
Welding torch
A
Complete documentation

For your safety
Safety instructions
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2.4 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!
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.

For your safety
Safety instructions
10
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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.
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!
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!